Electric Vehicle Service Technician

Par cipant Handbook

Sector
Automo ve

Sub-Sector
Automo ve Vehicle Service
Occupa on
Technical Service & Repair
Reference ID: ASC/Q1429, Version-4.0
NSQF Level: 4

Electric Vehicle
Service Technician
Scan this QR Code to access eBook
Par cipant Handbook

Developed by:
Automo ve Skills Development Council (ASDC)
ASDC Contact Details:
Leela Building, 153 GF, Industrial Area,
New Delhi, Delhi 110020
Email: [email protected]
Website: www.asdc.org.in
Phone: 011 4186 8090
 Electric Vehicle Service Technician

Skilling is building a be er India.

If we have to move India towards
development then Skill Development
should be our mission.

Shri Narendra Modi

Prime Minister of India
Par cipant Handbook

Certificate

is hereby issued by the

AUTOMOTIVE SKILLS DEVELOPMENT COUNCIL

for

Complying to National Occupational Standards of

Job Role/Qualification Pack: Electric Vehicle Service Technician QP Nos. ASC/Q1429 Level 4

Date of Issuance: 01/03/2021

Authorised Signatory
Valid up to : 25/02/2026 (Automotive Skills Development Council)
*Valid up to the next review date of the Qualification Pack or the
‘Valid up to’ date mentioned above (whichever is earlier)
 Electric Vehicle Service Technician

Acknowledgements
Automo ve Skill Development Council (ASDC) would like to express its gra tude to all the individuals
and ins tu ons who contributed in different ways towards the prepara on of this "Par cipant
Handbook". Without their contribu on it would not have been completed. Special thanks are
extended to those who collaborated in the prepara on of its different modules. Sincere apprecia on is
also extended to all who provided peer review for these modules. The prepara on of this Handbook
would not have been possible without the Automo ve Industry's support. Industry feedback has been
extremely encouraging from incep on to conclusion and it is with their input that we have tried to
bridge the skill gaps exis ng today in the Industry. This handbook is dedicated to the aspiring youth who
desire to achieve special skills which will be a lifelong asset for their future endeavours.
Par cipant Handbook

About this Book

Indian Auto Industry is one of the largest in the world. The industry is expected to contribute 10% to
India's GDP as per Automo ve Mission Plan 2016-26 and create 65 million addi onal jobs. The sector
offers big poten al for jobs across the length and breadth of the country. In line with the rapid
technological advancement in this field, there are exci ng prospects for a fulfilling career in this
industry.
This book is designed to enable a candidate to acquire skills that are required for employment. The
content of this book is completely aligned to the Na onal Occupa on Standards QP/NOS and conform
to the Na onal Skills Qualifica on Framework (NSQF).
The Qualifica on pack of Electric Vehicle Service Technician, Level 4 includes the following NOS's which
have all been covered across the units:
1. ASC/N9801: Organize Work and Resources (Service)
2. ASC/N1449: Carry out rou ne service or minor repairs on electric vehicle and assist in diagnosis
3. ASC/N1450: Carry out rou ne service or minor repairs on four wheeler electric/ hybrid vehicle and
assist in diagnosis
4. ASC/N1451: Carry out rou ne service or minor repairs on 2/3 wheeler electric vehicle and assist in
diagnosis
5. ASC/N1452: Carry out rou ne service or minor repairs on heavy commercial electric vehicle and
assist in diagnosis
Key Learning Objec ves for the specific NOS mark the beginning of the Unit/s for that NOS. The symbols
used in this book are described below.

Symbols Used

Key Learning Unit Tips Notes

Outcomes Objec ves
 Electric Vehicle Service Technician

Table of Contents
SI.No Modules and Units Page No

1. Introduc on to The Role of an Electric Vehicle Service Technician 1

Unit 1.1 - Role and Responsibili es of an EVST 3

Unit 1.2 - EV Manufacturing Market in India 6

Unit 1.3 - EV- Original Equipment Manufacturers 10

Unit 1.4 - Workshop Structure 21

Unit 1.5 - Maintenance Standards 24

2. Work Effec vely and Efficiently (ASC/N9801) 29

Unit 2.1 - Safe Working Prac ces 31

Unit 2.2 - Emergencies, Rescue and First Aid Procedures 38

Unit 2.3 - Workplace Quality Standards 51

Unit 2.4 - Health and Hygiene During an Epidemic and Pandemic 64

3. Op mize Resource U liza on (ASC/N9801) 76

Unit 3.1 - Resource Op miza on 78

Unit 3.2 - Waste Management 83

4. Perform rou ne service and repair of an Electric Vehicle (ASC/N1449) 88

Unit 4.1 - Prerequisites for Service and Repair of Electric Vehicles 90

Unit 4.2 - Prepare to Carry out Rou ne Service or Minor Repair 146

Unit 4.3 - Perform Rou ne Service or Minor Repair 153

5. Perform rou ne service and repairs of a four wheeler EV (ASC/N1450) 180

Unit 5.1 - Basics of a 4-Wheeler EV 182

Unit 5.2 - Rou ne Service and Repairs of a 4-Wheeler EV 193

6. Perform rou ne service and repairs of a 2/3 wheeler EV (ASC/N1451) 228

Unit 6.1 - Basics of Electric 2/3-Wheeler Vehicle 230

Unit 6.2 - Rou ne Service and Repairs on a 2/3-Wheeler EV 241

Par cipant Handbook

Table of Contents
SI.No Modules and Units Page No

7. Perform rou ne service and repairs of a truck/bus electric vehicle (ASC/N1452) 263

Unit 7.1 - Basics of Truck/Bus Electric Vehicle 265

Unit 7.2 - Rou ne Service and Repairs on a Truck/Bus Electric Vehicle 278

8. Employability and Entreprenuership Skills 312

The book on New Employability Skills is available at the following loca on

h ps://eskillindia.org/NewEmployability

9. Annexure 313

Annexure : QR Code 314

 Electric Vehicle Service Technician

1. Introduc on to
The Role of an
Electric Vehicle
Service Technician

Unit1.1 - Role and Responsibili es of an EVST

Unit1.2 - EV Manufacturing Market in India
Unit1.3 - EV- Original Equipment Manufacturers
Unit1.4 - Workshop Structure
Unit1.5 - Maintenance Standards

Bridge Module
1
Par cipant Handbook

Key Learning Objec ves

At the end of this module, you will be able to:
1. Discuss the role and responsibili es of an Electric Vehicle Service Technician

2
 Electric Vehicle Service Technician

Unit 1.1- Role and Responsibili es of an EVST

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. List the role and responsibili es of an Electric Vehicle Service Technician
2. Discuss the job opportuni es for an Electric Vehicle Service Technician in the automobile industry
3. Discuss the job opportuni es of an Electric Vehicle Maintenance Technician - Electrical

1.1.1 Introduc on to Automo ve Industry

The Automo ve industry is involved in the design, development, manufacturing, marke ng, selling and
servicing of motor vehicles. The word automo ve means any form of self-powered vehicle. Ini ally
automobiles were powered using steam, then fuel gas and now moving towards electric vehicles. The
following three pictures represent a steam tricycle, diesel motorbike and an electric scooter
respec vely.

Fig. 1.1.1 Steam Tricycle (Source: en.wikipedia.org)

Fig. 1.1.2 Diesel Motorbike (Source: en.wikipedia.org)

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Par cipant Handbook

Electric vehicles (EVs) run on electric motors that are

powered by chargeable ba eries. These vehicles are
environmentally friendly as they use very li le or no
fossil fuels (diesel or petrol). Electric vehicles were first
invented in the mid-19th century, when electricity was a
preferred method for motor vehicle propulsion as it
provided a level of comfort and ease of opera on that
was not achieved by petrol or diesel vehicles. They did
not do well in the market because of low speed, high
cost and short-range.Electric power remained in rail
vehicles (trains). In the 21st century, electric vehicles
saw a rebirth due to technological developments and
reduced nega ve impact on the environment Fig. 1.1.3 Electric Scooter (Source: www.bikewale.com)

1.1.2 Role and Responsibili es of Electric Vehicle Service

Technician (EVST)
The main responsibili es of an Electric Vehicle Service Technician are to carryout repair, rou ne
servicing and maintenance of Electric and Hybrid vehicles and assist the Electric Vehicle Lead Service
Technician.
The following are the role and responsibili es of an Electric Vehicle Service Technician related to various
aspects of work:

Repair, service and maintenance

• Be able to review the job card and take instruc ons form the senior.
• Be able to iden fy the various components related to mechanical and electric aggregates in the
electric vehicle.
• Have good knowledge of tools and equipment to be used for performing various tasks related to
fault finding, maintenance, service and repair.
• Be able to find minor faults in the components and rec fy.
• Be able to assist lead technician in diagnosis and troubleshoo ng the faults.
• Be able to report malfunc ons and repairs beyond own scope to the concerned person.
• Be able to check the vehicle post service/repair.

Health, safety and security policies and procedures

• Follow organiza on’s health, safety and security policies and procedures.
• Iden fy hazards and risks associated with work ac vi es, their causes and preven on.
• Iden fy and report breaches in health, safety and security procedures to the designated person.
• Maintain health and hygiene by following personal hygiene prac ces.
• Wear and dispose PPE appropriately.
• Ensure that the work area is clean, dy and safe.
• Follow appropriate waste management principles.

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 Electric Vehicle Service Technician

Organisa on and OEM guidelines and SOPs

• Follow organisa on guidelines and Standard Opera ng Procedures (SOPs).

• Follow Original Equipment Manufacturers (OEM) guidelines related to selec on and use of spare
parts and servicing procedures.

Documenta on, recording and repor ng

• Maintain a log of all the tasks performed, details of material used for servicing and repair work,
spare parts used, etc. as per the SOP.
• Should know the procedures for recording and repor ng faults, hazards and risks related to
health, safety and security to the designated people.

Personal a ributes

• Good communica on and interpersonal skills with colleagues, customers and others.
• Be pa ent and well organized in work, be able to work in a team and work for long hours.
• Be a keen observer with an eye for detail and quality.
• Have good physical stamina and stress management abili es.

Fig. 1.1.4 Role and Responsibili es of EVST

1.1.3 Job Opportuni es for Electric Vehicle Service Technician

By 2030, India is expected to have 30% of the vehicles in the market to be electric or hybrid vehicles. This
increasing demand for EVs will create a huge ecosystem of OEMs and component companies. Along with
the increase in manufacturing all the allied fields of EV industry will see a rise. For example: raw material
supplies, sales and distribu on, servicing, etc. According to Ministry of Skill Development and
Entrepreneurship, EV industry is es mated to provide around five crore direct and indirect job
opportuni es in India. About 15% of the total jobs in the automobile industry is in the service sector. EV
service technician can get jobs in OEM Authorized Service Centers and in private garages and
workshops. An EVST will be able to perform work related to the mechanical components like steering
gear, axle, suspension, brakes, etc. An EVST-Electrical can contribute in areas of ba ery management
system, charging system, powertrain, DC-DC convertors, power electronics components safety and
tes ng, etc.

Electric Vehicle Service

Electric Vehicle Lead Service Advisor Workshop
Service Technician Technician 7-10 years Manager
2-3 years experience 5-7 years experience
experience

Fig. 1.1.5 Career Progression of EVST

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Par cipant Handbook

Unit 1.2 - EV Manufacturing Market in India

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. Explain about Indian EV manufacturing market

1.2.1 Indian EV Manufacturing Market

In India, the automo ve sector is dominated by scooters, motorbikes and auto-rikshaws. The rising
demand for these vehicles, rising government emphasis, focus by government and private players
partnership to enhance the EV ecosystem, product launches by several automo ve companies and
increasing investment is expected to create a posi ve outlook in the market. The Indian electric vehicle
market is expected to register a CAGR (Compound Annual Growth Rate) of 47.09% during the forecast
period of 2022-2027.

1.2.1.1 Segmenta on of EV Market

The Indian electric vehicle market is segmented by vehicle type and propulsion type.
Based on Vehicle Type:

Commercial Passenger
Vehicles Vehicles

Three-wheelers Two-wheelers

Fig. 1.2.1 Segmenta on based on Vehicle Type

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 Electric Vehicle Service Technician

Based on Propulsion Type:

Ba ery Elecric Vehicle (BEV) Hybrid Electric Vehicle (HEV) &

Plug-in Hybrid Vechicle (PHEV)

Fuel Cell Electric Vehicle

(FCEV)
Fig. 1.2.2 Segmenta on based on Propulsion Type

1.2.1.2 Ini a ves to Promote EV Manufacturing in India

Government of India has taken many ini a ves to promote manufacturing and adop on of electric
vehicles in India to reduce emissions and also develop e-mobility. Some of the ini a ves are as follows:
Ÿ Faster Adop on and Manufacturing of Hybrid Electric Vehicles (FAME I and II) and Na onal Electric
Mobility Mission Plan (NEMMP) have helped develop the ini al interest for electric mobility.
Ÿ In FAME II, government is focusing on electrifica on of public and shared transporta on through
subsidizing around 10,00,000 electric two-wheelers, 5,00,000 electric three-wheelers, 5,50,00
electric passenger vehicles and 7,000 electric buses.
Ÿ Government of India has also provided tax exemp ons and subsidies to both Electric vehicle
manufacturers and consumers.
Ÿ Many states like Andhra Pradesh, Delhi, Karnataka, Kerala and Telangana have formulated electric
vehicle policies that support local manufacturing, research and development (R&D) and
infrastructure development.

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Par cipant Handbook

Ÿ Many start-ups and major automobile manufacturers are inves ng heavily to increase their
produc on capacity of electric two-wheelers in the country to cater to the increasing demand.
The following are some of the EV manufacturing companies inves ng to increase their produc on
capacity:

Fig. 1.2.3 Logo of Hero Electric

Hero Electric has received a funding of Rs. 220 crores and plans to use this fund towards expanding its
produc on capacity and R&D. Since 2011, the plant based in Ludhiana has manufactured and launched
over 15 electric two wheelers. In the first phase, the company is planning to increase the opera onal
produc on capacity to 5 lakh two-wheelers at its Ludhiana plant by mid-2022 and therea er, set up
capacity at a new loca on.

Fig. 1.2.4 Logo of Greaves Co on

Greaves Co on’s e-mobility wing Greaves Electric Mobility has opened a produc on facility at Ranipet
in Tamil Nadu which is spread over an area of 35 acres and built at a cost of Rs.700 crore aims to produce
1.2 lakh units every year. The facility will have 70 percent women workforce.

Fig. 1.2.5 Logo of Okinawa Autotech

Okinawa Autotech is a 100 percent electric two-wheeler manufacturing company based in Harayana.
The company has opened a second EV manufacturing plant in Bhiwadi, Rajasthan in February 2022. It
has a produc on capacity of 3 lakh units per year and plans to increase the produc on to 10 lakh units in
the next 2 to 3 years.

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 Electric Vehicle Service Technician

Fig. 1.2.6 Logo of Mahindra Electric

Mahindra Electric Vehicles manufacturing unit based in Bengaluru, Karnataka, is India’s first automobile
plant to be rated as ‘Pla num’ by India Green Building Council. It is an eco-conscious plant producing
vehicles for a greener tomorrow. In 2021, Bengaluru facility had a produc on capacity of 30 thousand
three-wheelers per year and plans scale-up to about 1 lakh units per year by 2024-25.

Fig. 1.2.7 Logo of Ola Electric

Ola FutureFactory, located in Pochampalli in Tamil Nadu is the world’s largest two-wheeler factory and
has integrated facility with manufacturing, ba ery as well as supplier parks in close proximity. It is spread
over a 500-acre campus and has a 10 million annual produc on capacity.

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Par cipant Handbook

Unit 1.3 - EV- Original Equipment Manufacturers

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. List various types of EV’s and different products/ models manufactured by Original Equipment
Manufacturers (OEMs)

1.3.1 Types of EV
As men oned in the previous unit, EV can be categorised into different types based on the type of the
vehicle and type of propulsion.

1.3.1.1 Type of Vehicle

There are four segments under the type of vehicle:

• Mopeds
Electric two-wheelers • Scooters
• Bikes

• Passenger auto
Electric three-wheelers
• Cargo auto

Electric Passenger Vehicles • Cars

Electric Commercial Vehicles • Buses

Fig. 1.3.1 Various segments of EV based on Type of Vehicle

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 Electric Vehicle Service Technician

1.3.1.2 Type of Propulsion

There are four segments under the type of vehicle:

Ba ery Electric Vehicle (BEV)

Ba ery Electric
packs motor

These are also known as All-Electric Vehicles

(AEV) or Pure Electric Vehicles (PEV). These
vehicles run en rely on ba ery-powered The main components of BEV are electric
electric drive train. The electricity required to motor, inverter, ba ery, control module and
drive the vehicle is stored in a large ba ery drive train.
pack. The ba ery pack can be charged by
plugging in to the electricity grid which
provides power to one or more
electric motors to run the
electric car.
Ba ery Electric Vehicle
Working principle of BEV: The (BEV)
power for the electric motor is
converted from Direct current
(DC) ba ery to Alterna ng
Current (AC). When the accelerator is pressed
a signal will be sent to the controller, which Examples of BEV are Hyundai Kona, MG ZS,
adjusts the speed of the vehicle by changing TATA Nexon, TATA Tigor, Mahindra E20 plus,
the frequency of the AC power from the Mahindra Verito
inverter to the motor. The motor then
connects and turns the wheels through a cog.
When the brakes are pressed, the motor acts
like an alternator and produces power which
is sent back to the ba ery

Fig. 1.3.2 Ba ery Electric Vehicle (Image Source: www.e-amrit.ni .gov.in)

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Par cipant Handbook

They are also known as parallel or series The main components of HEV are engine,
hybrid. HEVs have an engine and electric electric motor, ba ery pack with controller
motor, hence the name hybrid. The motor and inverter, fuel tank and control module.
gets electricity from ba eries and the
engine gets energy from fuel.

Hybrid Electric Vehicle

(HEV)
Working principle of HEV: Like
in a regular car, the fuel
supplies energy to the engine.
The ba ery provides energy to the motor. Examples of HEV are Ford C-Max, Honda
The engine and motor together turn the CR-Z, Kia Op ma Hybrid, Toyota Prius
transmission at the same me, which then
drives the wheels.

Fig. 1.3.3 Hybrid Electric Vehicle (Image Source: www.e-amrit.ni .gov.in)

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 Electric Vehicle Service Technician

They are also known as series hybrid. PHEVs

have an engine and a motor. To power the The main components of HEV are engine,
engine either conven onal fuel (like petrol) or electric motor, ba ery pack with controller
alterna ve fuel (like bio-diesel) can be and inverter, fuel tank and control module.
chosen. The motor gets powered by a ba ery
which can be charged externally.

Plug-in Hybrid Electric

Vehicle (PHEV)
Working principle of PHEV:
PHEVs can run either in the All-
electric mode or Hybrid mode.
In the beginning, PHEVs start in
the All-electric mode and uses the energy for
the motor un l the charge in the ba ery pack
is depleted. As soon as the ba ery is drained, Examples of PHEV are Hyundai Sonata,
the engine takes over and the vehicle works Ford C-Max Energi, BMW 330e, Porsche
as a conven onal non-plug-in hybrid. PHEVs Panamera S E-hybrid, Fiat 500e.
can be charged by plugging in to an outside
electric power source. When brakes are
applied, the motor acts as a generator and
uses the energy to charge the ba ery. Since
the engine’s power is supplemented by the
motor, smaller engines can be used. This
increases the car’s fuel efficiency with
compromising the performance.

Fig. 1.3.4 Plug-in Hybrid Electric Vehicle (Image Source: www.e-amrit.ni .gov.in)

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They are also known as Zero-Emission The main components of FCEV are electric
Vehicles. These vehicles generate the motor, fuel-cell stack, hydrogen storage
electricity required to run the vehicle in tank, ba ery with converter and controller.
the vehicle itself.

Fuel Cell Electric Vehicle

(FCEV)

Working principle of FCEV:

They use fuel cell technology,
in which the chemical energy of the fuel is Examples of FCEV are Honda Clarity Fuel
converted directly in to electric energy Cell, Hyundai Nexo, Toyota Mirai
required to run the vehicle.

Fig. 1.3.5 Fuel Cell Electric Vehicle (Image Source: www.e-amrit.ni .gov.in)

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 Electric Vehicle Service Technician

1.3.2 Original Equipment Manufacturer (OEM)

OEM refers to the original parts assembled and installed during the construc on of a new vehicle. OEM
components are the genuine official automo ve parts produced directly by the vehicle manufacturer.
OEM components and parts are guaranteed by the manufacturer to be compa ble with the vehicle.
Whereas a ermarket parts are those components made by companies other than the OEM. These may
be installed as replacements a er the vehicle comes out in the market. Customers may choose to
replace damaged vehicle components with OEM parts to ensure that the replacement parts are fully
compa ble with the vehicle and are produced at the same quality standards. OEMs o en sell their
components directly or through branded car dealers. OEM products are generally more expensive than
the a ermarket components.

1.3.2.1 Products manufactured by OEM

In an Electric Vehicle there are various mechanical and electrical components. Examples for mechanical
aggregates are suspension, steering gear, brakes, axle, etc. Examples for electrical aggregates are motor,
ba ery, charging systems, etc. Most of these products are produced by the OEMs.
Basic components in Evs:

Fig. 1.3.6 Motor(Source: www. tech.hyundaimotorgroup.com)

Motor: Motor converts the electric energy to kine c energy, which moves the wheels. The motor also
acts like an electric generator. For example: when a vehicle is decelera ng (slowing down or brakes are
applied), it converts the kine c energy to electric energy.

Fig. 1.3.7 Reducer (Source: www. tech.hyundaimotorgroup.com)

Reducer: It reduces the motor’s revolu ons per minute (RPM) to generate an appropriate level of force.

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Fig. 1.3.8 Ba ery (Source: www. tech.hyundaimotorgroup.com)

Ba ery: It is the equivalent of a fuel tank in an Internal Combus on Engine (ICE). The capacity of the
ba ery o en decides the driving distance of an EV. As the capacity of the ba ery increases, the driving
distance also increases.On-board Charger (OBC): It is used to convert Alterna ng Current (AC) from
portable chargers or slow chargers used on home outlets in to Direct Current (DC). OBCs are not
required in fast-charging, as fast chargers supply electricity as direct current.

Fig. 1.3.9 On-board Charger

(Source: www. tech.hyundaimotorgroup.com)

On-board Charger (OBC): It is used to convert Alterna ng Current (AC) from portable chargers or slow
chargers used on home outlets in to Direct Current (DC). OBCs are not required in fast-charging, as fast
chargers supply electricity as direct current.

Fig. 1.3.10 Electric Power Control Unit (EPCU)

(Source: www. tech.hyundaimotorgroup.com)

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Electric Power Control Unit (EPCU): EPCU integrates almost all the devices that control the flow of
electric power in the vehicle. It consists of Low voltage DC-DC Converter (LDC), Vehicle Control Unit
(VCU) and inverter.

The following table shows the various EV Components manufacturers in India:

Company Name Loca on Company website Components

Minda Industry New Delhi www.unominda.com Lights, switches,

sensors, brakes, and
other parts

Amara Raja Tirupa , Andhra www.amararajaba eries.com EV Ba eries

Ba eries Ltd. Pradesh

GoGoA1 Navi Mumbai, www.gogoa1.com EV conversion kit,

Maharastra connectors, chargers
and lights,

Greenful energy Manesar, Haryana www.greenfuelenergy.in Ba ery, power train,

BMS, motor and
controller

Okaya ba ery New Delhi www.okayapower.com Lithium-Ion ba eries

Jayem Coimbatore, Tmail www.jayemauto.com BMS, power train,

Automo ve Nadu ba ery, motor and
other components

Napino Manesar, Haryana www.napino.com EV ba eries, motors,

chargers, BMS, and
many other suppor ng
components for
electric vehicles

Electra EV Pune, Maharastra www.electraev.com Complete power train

for EV

Elecnovo Bengaluru, www.elecnovo.com Electric vehicle motors

Karnataka and controllers

Exicom Power Gurgoan, Haryana www.exicom-ps.com Lithium-ion ba eries,

Solu on charging system, and
BMS

Auto Die Cast New Delhi www.evdiecast.com Vehicle body and

structure

Con nued...

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Par cipant Handbook

Company Name Loca on Company website Components

Rizel Automo ve Hyderabad, www.rizelautomo ve.com Electric motors

Telangana

EV Ba ery Bengaluru, www.evba erysolu ons.com Lithium ba eries

Solu on Karnataka

Karacus Energy New Delhi www.karacusenergy.com Lithium-ion ba eries

Compage Faridabad, www.compageauto.com Electric motors

Automa on Haryana

Trontek New Delhi www.trontek.com Ba eries and

electronic components

Fiem Industry Sonepat, Haryana www.fiemindustries.com Lights, side mirrors,

indicators and info
display panels

Bharat Power Noida, U ar www.bpsba eries.com EV ba eries

Solu on Pradesh

Kitra Industries Surat, Gujarat www.kitraind.com Copper die cast rotors

for induc on motor in
EV

Table 1.3.1 EV Components Manufacturers in India

1.3.2.2 OEM models manufactured in India

In India, the EV sector is dominated by two-wheelers (scooters, motorbikes), three-wheelers (passenger
autos, cargo autos) and four-wheelers (passenger cars). There were 380 EV manufacturers in India ll
31st July 2021. The approved models by FAME-II along with their manufacturers are as shown below:

Manufacturers (2 wheelers) No. of Models Approved

Ampere Vehicles Pvt. Ltd. 6

Ather Energy Pvt. Ltd. 3

Baja Auto Ltd. 2

Benling India Energy and Technology Pvt. Ltd. 1

Con nued...

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 Electric Vehicle Service Technician

Manufacturers (2 wheelers) No. of Models Approved

Hero Electric Vehicles Pvt. Ltd. 10

Jitendra New EV Tech Pvt. Ltd. 3

Li-ions Elektrik Solu ons Pvt.Ltd. 1

M/s Tunwal E-motors Pvt. Ltd. 5

Micron I2i Pvt. Ltd. 1

Okinawa Autotech Pvt. Ltd. 4

Revolt Intellicorp Pvt. Ltd. 2

TVS Motor Company Pvt. Ltd. 1

Table 1.3.2 Manufacturers of approved Two-wheeler models by FAME II

Manufacturers (3 wheelers) No. of Models Approved

Atul Auto Ltd. 2

Avon Cycles Ltd. 2

Best Way Agencies Pvt.Ltd. 2

Champion Polyplast 3

Dilli Electric Auto Pvt.Ltd. 2

Energry Electric Vehicles 1

Etrio Auto mobiles Pvt.Ltd. 3

Euler Motors Pvt.Ltd. 2

Goenka Electric Motor Vehicles Pvt.Ltd. 3

Grd Motors 1

Jitendra New EV Tech Pvt.Ltd. 3

Keto Motors Pvt.Ltd. 5

Khalsa Agensies 1

Kine c Green Energy and Poer Solu on Ltd. 5

Lohia Auto Induatries 3

M/s. Speego Vehicles CO. Pvt.Ltd. 1

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Manufacturers (3 wheelers) No. of Models Approved

Mahindra Electric Mobility Ltd. 7

Mir Auto Ltd. 1

Om Balajee Automobile India Pvt.Ltd. 2

Omega Seiki 1

Piaggio Vehicles Pvt.Ltd. 9

Saera Electric Auto Pvt.Ltd. 1

Scooters India Ltd. 1

Shigan Evoltz Ltd. 3

SKS Trade India Pvt.Ltd. 1

Thukral Electric Bikes Pvt.Ltd. 2

U.P. Telelinks Ltd. 4

Victory Electric Vehicles Interna onal 4

Y.C. Electric Vehicle 2

Table 1.3.3 Manufacturers of approved Three-wheeler models by FAME II

Manufacturers (4 wheelers) No. of Models Approved

Al green Propulsion Labs Pvt. Ltd. 4

Mahindra & Mahindra Ltd. 8

Tata Motors Ltd. 11

Table 1.3.4 Manufacturers of approved Four-wheeler models by FAME II

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Unit 1.4 - Workshop Structure

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. Illustrate the workshop structure
2. Describe role and responsibili es of different people in the workshop

1.4.1 Structure of Workshop

An automobile workshop or service sta on is a place where service, maintenance and repair work of
automobiles is carried out. Most o en they also sell lubricants, ba eries, small accessories, spare parts,
tyres, etc. Large OEMs have their own workshops or cer fied workshops. There are many smaller private
workshops as well servicing mul ple models of vehicles.
The following figure shows the structure of a typical EV workshop:

Workshop
Manager

Customer EV Spare Parts

Bodyshop
Care Service Opera on
In-Charge
Manager Manager In-Charge

Customer Internal EV Body EV Body Spare Parts

Service Service Waranty
Rela on Trainer Repair Paint Opera on
Advisor Supervisor In-Charge
Execu ves Service Technician Technician Execu ve

Driver- EV Sevice EV EV
AC
Pick Lead Service Accessory Washer
Specialist
and Drop Technician Technician Fi er

Fig. 1.4.1 Structure of EV Workshop

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Par cipant Handbook

1.4.2 Role and Responsibili es of People in the Workshop

An EV workshop can be broadly divided in to four major sec ons i.e., Customer Care sec on, Service
sec on, Bodyshop sec on and Spare Parts sec on. Each of these sec ons have a sec on
head/manager/in-charge, who oversee the opera ons in their respec ve sec ons. The workshop
manager oversees the opera on of the en re workshop.

Workshop Manager
Oversees the en re opera ons of a workshop. Customer Care Manager, EV Service Manager,
Bodyshop In-Charge and Spare Parts Opera on In-Charge report to the Workshop Manager.

Customer Rela on EV Service Manager Bodyshop In-Charge Spare Parts In-Charge

Manager (CRE) Oversees all the Is responsible for Oversees opera on
Oversees the opera ons related to overseeing opera ons related to issuing of
opera on related to servicing of the related to repairing spare parts as per the
interac ng with vehicles., training, the body and frame of organisa on and OEM
customers, taking service advise and an EV due to a SOPs. Spare Parts
their feedback, warranty. Internal damage like an Opera on Execu ves
organizing service Trainer Service, accident. EV Body report to Spare Parts
appointments, etc. Service Advisor, Repair Technician and In-Charge.
Customer Care Service Supervisor EV Body Paint
Execu ves report to and Warranty In- Technician report to
CRE. Charge report to EV Bodyshop In-Charge.
Service Manager.

Fig. 1.4.2 Role and Responsibili es of EV Workshop Manager and team

EV Service Manager

Internal Trainer Service Advisor Service Supervisor Warranty In-Charge

Service Is responsible for Oversees all the Takes care of ma ers
Is responsible for providing advice for opera ons related to related to spare part
impar ng training to complex problems service, repair, warranty,
all the workers related and troubleshoo ng maintenance, vehicle management of
to servicing, repair situa ons in servicing, body works, ACs, warranty claims, etc.
and maintenance of repair and accessories and
the vehicle. maintenance of the washing. EV Service
vehicle. Assigning jobs Lead Technician
to technicians, (EVSLT), EV Service
opening job cards, Technician (EVST), AC
a er-service Specialist, EV
inspec on and road Accessory Fi er and
test. Washer report to EV
Service Supervisor.

Fig. 1.4.3 Role and Responsibili es of EV Service Manager and team

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 Electric Vehicle Service Technician

Service Supervisor

EVSLT EVST AC Specialist EV Accessory Washer

Is responsible for Is responsible for Is responsible for Fi er Is Is responsible
diagnosing faults, diagnosing minor inspec ng, responsible for for washing,
carrying out faults, carrying repairing and the up-keep and scrubbing and
major out minor servicing of the refurbishing of polishing the
repairs/overhauli repairs/overhauli Air-condi oner in the accessories in vehicle
ng of aggregates. ng of aggregates. the vehicle. the vehicle. exteriors and
EVST and EVST- interiors.
Electrical report
to EVSLT.

Fig. 1.4.4 Role and Responsibili es of EV Service Supervisor and team

Bodyshop In-Charge

EV Body Repair Technician EV Body Paint Technician

Is responsible for repairing the body of the Is responsible for pain ng and applying
vehicle like removing dents, nkering, other coa ngs on the damaged parts and
replacing broken body parts, etc. body of the vehicle.

Fig. 1.4.5 Role and Responsibili es of EV Bodyshop In-Charge and team

Spare Parts In-Charge

Spare Parts Opera on Execu ves

Is responsible to issue spare parts and maintain a log.

Fig. 1.4.6 Role and Responsibili es of EV Spare Parts In-Charge and team

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Par cipant Handbook

Unit 1.5 - Maintenance Standards

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. Illustrate the workshop structure
2. Describe role and responsibili es of different people in the workshop

1.5.1 Organisa on Maintenance Standards and Procedures

Maintenance Standard Opera on Procedures (SOP) is a document consis ng of step-by-step
instruc ons to be followed for maintenance the workers/technicians need to follow during
maintenance of vehicles. It clearly defines the expected quality standards and expected prac ces by the
organisa on. The steps included in a maintenance SOP are generally in accordance to the law, industry
regula ons and company standards. SOPS are developed for rou ne and repe ve maintenance tasks.
They are generally not s pulated for cri cal decision making and complicated problem-solving issues.
Maintenance SOPs are prepared for the following tasks/processes:

Rou ne inspec ons

Preven ve maintenance scheduling

Work order crea on, management and comple on

Assigning of shi -wise maintenance tasks to workers

Data entry/documenta on of maintenance management systems

Maintenance inventory management

Fig. 1.5.1 Tasks/Processes for which Maintenance SOPs are prepared

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 Electric Vehicle Service Technician

The following details should be a part of Maintenance SOP:

Step-by-step procedures for the maintenance tasks to be performed.

The sequence or order in which the tasks are to be performed.

Skills that are required to perform a certain maintenance task.

List of equipment, tools, components and PPE to be used to perform the task.

Instruc onal manuals, drawings, reference documents, etc. Required

to perform the tasks.

Recording and repor ng of tasks.

Documenta on of all tasks and processes.

Compliance standards required by the OEM.

Fig. 1.5.2 Suggested details in Maintenance SOPs

1.5.2 Standard Checklists and schedules recommended

by OEM
Electric Vehicles require maintenance far lesser and frequent maintenance than ICE vehicles. Preven ve
maintenance pf EV helps in avoiding breakdowns and costly repairs; and ensure safety. Some of the
recommended maintenance steps by OEMs include inspec on of tyres wear and tear, checking tyre
pressure, inspec on and replacement of filters, wheel alignment, windscreen wiper replacement,
brake-fluid change, etc. Every vehicle has OEM guidelines and all servicing, maintenance and repairing
has to be done in accordance to the OEM guidelines. This helps in maintaining quality, consistency and
performance of the vehicle.
OEMs provide a maintenance scheduled based on a certain me line or based on the milage covered by
the vehicle for inspec on, servicing and replacement of parts. The sugges on given by OEMs is based on
informa on gathered through experiments and test runs. The following is an example of the
maintenance schedule provided to the consumer detailing the kind of maintenance that will be taken up
periodically:

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Par cipant Handbook

Fig. 1.5.3 Standard Checklist and Schedules recommended by Hero Electric for Bikes

VRLA Ba ery Service Matrix

Complete ba ery serial No. Last 4 Digits of each cell Booklet No.
HE-______________
A: B: C: D:

Service Par culars Refrence to Ba ery CDC & Job Card No Dealer Stamp &
Time Vehicle head light Levelled (Tick) & Date Signature
(Enter Seq.)

At the me Sequence
of Delivery

1st Service Sequence

(A er Rota on)

2nd Service Sequence

(A er Rota on)

3rd Service Sequence

(A er Rota on)

4th Service Sequence

(A er Rota on)

5th Service Sequence

(A er Rota on)

6th Service Sequence

(A er Rota on)

*Ba ery Leverling: Connect all va eries in parallel , and leave them for at least 1 hour for equaliza on of voltage
Fig. 1.5.4 VRLA Ba ery Service Matrix recommended by Hero Electric for Bikes

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 Electric Vehicle Service Technician

Summary
• The Automo ve industry is involved in the design, development, manufacturing, marke ng, selling
and servicing of motor vehicles.
• The word automo ve means any form of self-powered vehicle. Ini ally automobiles were powered
using steam, then fuel gas and now moving towards electric vehicles.
• Electric vehicles (EVs) run on electric motors that are powered by chargeable ba eries.
• These vehicles are environmentally friendly as they use very li le or no fossil fuels (diesel or petrol).
• The main responsibili es of an Electric Vehicle Service Technician are to carryout repair, rou ne
servicing and maintenance of Electric and Hybrid vehicles and assist the Electric Vehicle Lead Service
Technician.
• According to Ministry of Skill Development and Entrepreneurship, EV industry is es mated to
provide around five crore direct and indirect job opportuni es in India. About 15% of the total jobs
in the automobile industry is in the service sector.
• EV service technician can get jobs in OEM Authorized Service Centers and in private garages and
workshops.
• The rising demand for these vehicles, rising government emphasis, focus by government and private
players partnership to enhance the EV ecosystem, product launches by several automo ve
companies and increasing investment is expected to create a posi ve outlook in the market.
• The Indian electric vehicle market is segmented by vehicle type and propulsion type.
• Government of India has taken many ini a ves to promote manufacturing and adop on of electric
vehicles in India to reduce emissions and also develop e-mobility.
• EV manufacturing companies like Hero Electric, Greaves Co on, Okinawa, Mahindra Electric and
Ola Futurefactory are inves ng to increase their produc on capacity.
• EV are divided into various segments based on type of vehicle as Electric two-wheelers, Electric
three-wheelers, Electric passenger vehicles and Electric commercial vehicles.
• EV are divided into various segments based on type of vehicle as Ba ery Electric Vehicle (BEV),
Hybrid Electric Vehicle (HEV), Plug-in Hybrid Electric Vehicle (PHEV) and Fuse Cell Electric Vehicle
(FCEV)
• OEM refers to the original parts assembled and installed during the construc on of a new vehicle.
OEM components are the genuine official automo ve parts produced directly by the vehicle
manufacturer. OEM components and parts are guaranteed by the manufacturer to be compa ble
with the vehicle.
• In an Electric Vehicle there are various mechanical and electrical components. Examples for
mechanical aggregates are suspension, steering gear, brakes, axle, etc. Examples for electrical
aggregates are motor, ba ery, charging systems, etc. Most of these products are produced by the
OEMs.
• In India, the EV sector is dominated by two-wheelers (scooters, motorbikes), three-wheelers
(passenger autos, cargo autos) and four-wheelers (passenger cars). There were 380 EV
manufacturers in India ll 31st July 2021.
• An automobile workshop or service sta on is a place where service, maintenance and repair work of
automobiles is carried out. Large OEMs have their own workshops or cer fied workshops.

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Par cipant Handbook

• An EV workshop can be broadly divided in to four major sec ons i.e., Customer Care sec on, Service
sec on, Bodyshop sec on and Spare Parts sec on. Each of these sec ons have a sec on
head/manager/in-charge, who oversee the opera ons in their respec ve sec ons. The workshop
manager oversees the opera on of the en re workshop.
• Maintenance Standard Opera on Procedures (SOP) is a document consis ng of step-by-step
instruc ons to be followed for maintenance the workers/technicians need to follow during
maintenance of vehicles.
• Every vehicle has OEM guidelines and all servicing, maintenance and repairing has to be done in
accordance to the OEM guidelines. This helps in maintaining quality, consistency and performance
of the vehicle.

Exercise
Answer the following ques ons:
1. What are the roles and responsibili es of an EVST?
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
2. Discuss the different categories of EVs.
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

Scan the QR Code to watch the related video

www.youtube.com/watch?v=Pou7qc_BzU8
Introduc on to Automo ve Industry

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 Electric Vehicle Service Technician

2. Work Effec vely

and Efficiently

Unit 2.1 - Safe Working Prac ces

Unit 2.2 - Emergency Rescue and First Aid Procedures
Unit 2.3 - Workplace Quality Standards
Unit 2.4 - Health and Hygiene During an Epidemic and
Pandemic

ASC/N9801
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Par cipant Handbook

Key Learning Objec ves

At the end of this unit, the trainee will be able to:
1. List the poten al workplace related risks and hazards, their causes and preven ons
2. Iden fy safety measures during work
3. Display the correct way of wearing and removing PPE such as face masks, hand gloves, face shields,
PPE suits, etc
4. Show how to deal with a fire accident;
5. Demonstrate how to evacuate the workplace in case of an emergency
6. Demonstrate basic first aid techniques during electric shock, burns and choking
7. State the methods to keep the work area clean and dy
8. Perform rou ne cleaning of tools, equipment and machines
9. Apply basic housekeeping prac ces to ensure that the work area is clean, such as mopping spills and
leaks, cleaning grease stains etc
10. Discuss how to complete the given work within the s pulated me period
11. Discuss ways to maintain a proper balance between team and individual goals
12. Discuss epidemics and pandemics and their impact on society at large
13. Explain the significance of following prescribed rules and guidelines during an epidemic or a
pandemic
14. Discuss the significance of conforming to basic hygiene prac ces such as washing hands, using
alcohol-based hand sani zers
15. Show how to sani ze and disinfect one’s work area regularly
16. Demonstrate the correct way of washing hands using soap and water
17. Demonstrate the correct way of sani zing hands
18. Demonstrate appropriate social and behavioural e que e(gree ng and mee ng people,
spi ng/coughing/sneezing, etc.)
19. Discuss the ways of dealing with stress and anxiety during an epidemic or a pandemic

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 Electric Vehicle Service Technician

Unit 2.1 - Safe Working Prac ces

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. Elaborate importance of safety at workplace
2. List the poten al workplace related risks and hazards, their causes and preven ons
3. Iden fy safety measures during work
4. Display the correct way of wearing and removing PPE such as face masks, hand gloves, face shields,
PPE suits, etc

2.1.1 Health, Safety and Security Procedure

Health, safety and security procedures refer to the guidelines and rules that make sure that people in the
workplace, whether they are employers, employees or other visitors are safe and secure. These
procedures tell employees or employers how they should carry out their tasks around the workplace in a
way that ensures a minimiza on in accidents, incidents, contrac on of diseases and security breaches.
These sorts of preventa ve procedures may include:
Ÿ Educa ng staff on manual handling, i.e. how to li and move objects properly to avoid an injury
Ÿ Educa ng staff on how to minimize back and neck pain by using ergonomic furniture in an
appropriate fashion
Ÿ Giving detailed instruc ons on how to use equipment
Ÿ Educa ng staff on the importance of wearing appropriate protec ve gear to handle certain pieces
of equipment
Ÿ Instruc ng staff on how to keep the workplace secure, by teaching them about the security
systems in place and how to use them so that cash, equipment and people are safe and secure
Ÿ Educa ng staff on poten al hazards in the workplace
Ÿ Health, safety and security procedures also refer to what you should do when accidents or
incidents do occur

2.1.2 Importance of Safe & Secure Working Place

When we feel safe and secure, we can remain mo vated and feel happy at our workplace. Workplace
safety play an important role in organiza on as it boosts the produc vity. If the workers in the
organiza on feel safe they can work with their full capabili es and poten al and it also reflect posi vism
in the working environment. Therefore, measures needs to be taken to eliminate risks at work and
ensure a safe and comfortable environment for the employees.

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2.1.3 Responsibili es for Maintaining Safe Workplace

The responsibili es of the employers for maintaining safe workplace are:
Ÿ Healthy workplace should be provided
Ÿ Train the worker as per their job profile
Ÿ Maintain training records (who, what and when)
Ÿ Establish and maintain a comprehensive occupa onal health and safety program, including a wri en
Ÿ Support supervisors, safety co-ordinators and workers in their health and safety ac vi es
Ÿ During poten al hazard repor ng ac on should be taken immediately
Ÿ During incident instant inves ga on should be ini ated
Ÿ Provide adequate first aid facili es and services
Ÿ Ensure supply of personal protec ve equipment as per nature of job Worker training is usually
carried out by the supervisor. However, the employer has the legal responsibility to ensure that every
worker receives adequate training. The employer must follow up to see that the supervisor is carrying
out all the required training. Employers should also work with supervisors to help foster posi ve
worker a tudes to safety, health & safety policy and an incident inves ga on procedure.
The responsibili es of the supervisors for maintaining safe workplace are:
Ÿ Instruct workers to follow safety procedures
Ÿ Train workers on tasks assigned to them, and check that their safety at work
Ÿ Make sure that only authorized, adequately trained workers operate tools and equipment or use
hazardous chemicals
Ÿ Check out that equipment and materials are handled properly, stored and maintained
Ÿ Enforce health and safety requirements
Ÿ Take correc ve measures on unsafe acts and condi ons
Ÿ Iden fy and help workers with problems who could affect safety at the worksite
Ÿ Develop health and safety rules and inspect the workplace for hazards
The responsibili es of the workers for maintaining safe workplace are:
Ÿ Know and follow health and safety requirements affec ng your job
Ÿ If you don’t know how to do something safely, ask for training before you begin work
Ÿ Work safely, and encourage your co-workers to do the same
Ÿ Correct any unsafe condi ons or immediately report them to your supervisor
Ÿ Immediately report any injury to a first aid a endant or supervisor
Ÿ Take the ini a ve. Make sugges ons to improve health and safety

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 Electric Vehicle Service Technician

2.1.4 Workplace Hazards

The situa on which can create threat to human life, property of workplace or environment is defined as
hazard. Most of the hazards are hidden in nature which reflects theore cal risk but the fact is that if it
becomes ac ve it may lead to emergency. Situa on of hazard when finish it turns to be in incident.
Hazard and its possibility of ge ng ac vated act together to form a risk. Iden fica on of hazard risks is
the first step in performing a risk assessment.

Fig: 2.1.1 Auto workshop Hazards

Hazards are generally classified into three categories:

Ÿ Dormant: The circumstance project a possibility of ac ve hazard but it does not affect people,
property or environment. For instance, a hillside may be unstable, with the poten al for a landslide,
but there is nothing below or on the hillside that could be affected.
Ÿ Armed: People, property or environment is in poten al harm’s way.
Ÿ Ac ve: A dangerous occurrence in which hazard has played its role. It is some mes referred as
accident, emergency, incident or disaster not hazard.
The common types of hazard are:
Ÿ Physical hazards - A situa on which cause physical harm to body or create extreme stress is referred
as physical hazard. A physical hazard may be natural or human made also.
Ÿ Chemical hazards are substances which can create harm to human health, harm body parts, property
or environment. Chemical hazard may be natural or human made also.
Ÿ Biological hazards - In this type of hazard biological agents plays a crucial role can cause harm to
human health or body parts. These biological agents can be fungus, bacteria, viruses, parasites and
foreign toxins.
Ÿ Psychological hazards usually taken place due to stressful working environment. Here poten ally a

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Par cipant Handbook

person could be a hazard when affected psychological disturbance through stress or shi pa erns
and when a person is under the influence of alcohol, illness and lack of training.
Ÿ Electrical hazards are dangerous condi on where a worker can or does make electrical contact with
equipment or a conductor. From that contact, the person may sustain an injury from shock, and there
is a poten al for the worker to receive burn or blast injury.

Ac vity
Choose any of areas of your workplace, home, market, locality, schools, etc., and look for hazardous
situa ons that can cause injuries to people.
For each hazard you find, write:
Ÿ Why it is dangerous?
Ÿ What would happen if the hazard wasn’t rec fied?
Ÿ Two op ons for correc ng the situa on
Ÿ Who should be informed of the hazard (someone in a posi on of responsibility)?
Submit your findings in a wri en form (in the form of a report) to your facilitator in the next session.

2.1.5 Auto Shop Safety

Safety at automobile workshop
Ÿ Personal Safety: Observe the following general safety
precau ons while working in automo ve workshop
Ÿ Don’t indulge in horseplay
Ÿ Don’t sca er the tools etc. on the opera ng machinery
Ÿ Don’t keep sharp objects or tools in your pocket
Ÿ See that your dress is suited to the job. It should not be
loose which may get caught in the moving machinery
Ÿ Never use compressed air for blowing out dirt from Tour Fig: 2.1.2 Wear Safety Glasses While using a
clothes Grinder

Ÿ While chipping, grinding or using air hose or doing any other

job where there is danger of flying par cles, goggles must be worn.
Ÿ When car is jacked up, make sure the jack is properly centered and will not slip.

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 Electric Vehicle Service Technician

Fig: 2.1.3 Wear Safety Glasses While using a Grinder Fig: 2.1.4 Vehicle on jacks

Safety with hand tools

Ÿ Use the correct tool for the job in hand
Ÿ Use the tool correctly
Ÿ Keep the tools clean and in good working condi on
Ÿ Grease or oil on tools should be wiped off as it is difficult to hold and use such tools
Ÿ Store the tools in their proper places
Safety with power tools
Ÿ Electric shock: The safety precau ons are —
} Don’t use damaged chords
} Don’t stand in water or even wear wet shoes when working with electrical equipment
} Make sure the electrical equipment is properly earthed
Ÿ Flying metal chips the safety precau ons is — ALWAYS WEAR GOGGLES
Ÿ Injuries due to unsafe use of tools: The safety precau ons are:
} Carefully study the instruc ons before using any equipment
} Keep hands and clothes away from moving parts
} Make sure the electrical equipment is properly earthed
} When working on devices like clutches, valves etc. which have springs, make sure the springs will
not slip or jump off
} Don’t adjust or oil moving part of a machine
Ÿ Store the tools in their proper places

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Par cipant Handbook

2.1.6 Personal Protec ve Clothing

Firstly on shop floor every person has to wear person protec ve equipment (PPE) for its personal safety
What is Personal Protec ve Equipment?
Ÿ PPE is defined as “All equipment which protects the worker from risks and hazards while working at
workplace”
Ÿ Personal Protec ve Equipments safeguard us from work place hazards

Fig: 2.1.5 PPE

Eye Protec on: Eye protec on is a must when working on cars. Eyes are so fragile. Safety glasses and
goggles will help prevent foreign materials from entering your eyes. These are
especially important when inspec ng the underbody of a vehicle and working
around chemicals. Goggles can be used over prescrip on glasses
Gloves: Use work gloves when you are performing work on tyres or exhaust.
Extremely worn tyres can have sharp steel belts poking from the tread.
Exhaust systems can be hot and have rusty holes that can cut your hands. Use
disposable latex gloves when you are working with chemicals, oils, and grease.

Fig: 2.1.6 Safety gloves

Head Protec on: Hard hats guards from collision and penetra on hazards also
from burns and electrical shock hazards. Make sure that head protec on is
available where following risks can happen:
Ÿ Falling objects
Ÿ Contact of head with electricity sources accidently
Foot Protec on: Safety boots guard the feet from puncture wounds, injuries
Fig: 2.1.7 Safety hat
and slipping. Make sure that foot protec on is available where following risks
can happen:
Ÿ When heavy objects roll on or fall on the feet;
Ÿ Working with pointed items like nails or wires
Ÿ Risk if falling of molten metal on feet or legs;
Ÿ Working on warm, damp and greasy surfaces.

Fig: 2.1.8 Safety shoes

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 Electric Vehicle Service Technician

Ear Protec on: Use earplugs or earmuffs when the work area is excessively
loud. Noise with high decibel levels can damage your hearing. Earplugs are
made of waxed co on, foam, silicone rubber or fiberglass wool. They are self-
forming and, when properly inserted, they work as well as most molded
earplugs. Earplugs save the ears from loud noise at the workshop.

Body Protec on: There are many varie es of protec ve clothing available for
specific hazards. Protec ve clothing comes in a variety of materials, each Fig: 2.1.9 Ear plugs
effec ve against par cular hazards, such as:
Ÿ Paper-like fiber used for disposable suits provide protec on against dust
and splashes.
Ÿ Treated wool and co on adapts well to changing temperatures, is
comfortable and fire-resistant and protects against dust, abrasions and
rough and irrita ng surfaces.
Ÿ Leather is o en used to protect against dry heat and flames.
Ÿ Rubber, rubberized fabrics, neoprene and plas cs protect against certain Fig: 2.1.10 Safety dress
chemicals and physical hazards.

Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________

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Par cipant Handbook

Unit 2.2 - Emergencies, Rescue and First Aid Procedures

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. Discuss the causes of fire at the shop floor
2. Demonstrate steps of emergency procedures
3. Demonstrate steps to evacuate in emergency situa on
4. Demonstrate basic first aid techniques

2.2.1 Fire Hazards

Fire is one of the most common causes of the accidents in establishments. Fire is defined as a self
sustaining combus on process in which a substance (fuel) combines with oxygen in air to produce
immense heat and light.
Fire hazards pose threats to life and property. It is, therefore, the
prime object of safety systems to detect, remove or reduce the risk of
fire threatened by those poten al hazards.
The following fire hazards are common at home, in public places,
transports and work places:
Ÿ All types of flames used for any work
Ÿ Electric wires, higher loads, loose connec ons and old electrical
Fig: 2.2.1 Fire
equipment
Ÿ All cooking and heat genera ng appliances
Ÿ All works and situa ons where fire is essen al such as welding, cu ng, metal cas ng etc.
Ÿ Improper stowage of tools, equipment and items during and at the end of the day’s work
Ÿ Smoking and personal lighters and matches
Ÿ Fireworks, pyro techniques, ammuni ons and explosives
Ÿ Improper and unauthorized stowage of flammable and hazardous materials and chemicals especially
the flammable ones
Ÿ Insufficient capacity and numbers of emergency exits and stairs
Ÿ Hindrance to sight or reach fire figh ng equipment, markings and alarm systems
Ÿ Insufficient numbers and types of fire ex nguishers
Ÿ Absence of fire detec on and alarm system
Ÿ Viola on of building and fire codes

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 Electric Vehicle Service Technician

2.2.2 Fire Preparedness Procedures

Follow these emergency instruc ons in case of fire:
Ÿ Ac vate the ALARM.
Ÿ Evacuate the area.
Ÿ Call the fire department.
Ÿ Fight the fire only if:
} You know how.
Fig: 2.2.2 Fire Safety
} The fire is small.
} You are confined to the area where it started.
} You have a way out.
} You can work with your back to the exit.
} You have the right type of ex nguisher.
} You feel confident that you can operate it effec vely.
Ÿ DO NOT fight the fire if:
} You have any doubts about figh ng it.
} It is spreading beyond the area where it started.
} It could block your escape route.
Evacuate the building immediately Confine a fire to the zone of origin, for a specified me, thereby
preven ng fire spread and leaving more me for safe evacua on of the building occupants.
If a fire breaks out, smoke containment systems prevent the movement of smoke and heat from one area
to another.

2.2.3 Fire Preven on

Follow these steps for fire preven on:
Ÿ Don’t allow trash and li er to accumulate unnecessarily
Ÿ Keep the workplace areas neat and clean
Ÿ Know where fire alarm boxes and ex nguishers are located
Ÿ Ensure you know the different types of fire ex nguishers and how to use them
Ÿ Store hazardous materials in designated areas
Ÿ Keep exits free of obstruc ons
Ÿ Know loca on of emergency exits and procedures
Ÿ Handle flammable liquids with cau on

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Par cipant Handbook

2.2.4 Fire Ex nguishers

Types of fire
There are different classes of fire and each class of fire has different proper es and different mediums of
ex nguishing. Let’s discuss this here:

Class of fire Description Mode of Medium of Type of Ex nguisher

Ex nguishing Ex nguishing

Fire involving solid Cooling Water • Water

material (fuel) • Sode acid type
for combus on • CO2 gas type
like wood , paper
plas c that melt

Fire involving Blanketing Foam, CO2, • Foam

flammable liquids Halon and • CO2 gas type
like petrol, diesel, DCP • DCP
thinner, cooking • Halon type
oils, paints, wax
And plas c

Fire caused Cu ng of Vaporising • CO2

by electricity Electricity Liquids, dry • DCP
Equipment supply powder and • Halon
co2 • Dry sand

Fire involving Smothering Suitable dry • Special DCP

flammable metals Powder ex nguisher
like magnesium, • Dry sand
tanium • Powdered graphite
• Talc and asbestos
• Limestone

Table 2.2.1 Types of fire

Different types of fire-ex nguishers used in industry and their uses are:

Fire Ex nguisher Uses

Water • Pressurized, pumps type

• Cools Fire
• Use on Class A fires
• Do not use on B or C fires

Con nued...

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 Electric Vehicle Service Technician

Fire Ex nguisher Uses

Mul Purpose Dry Chemical • Stored pressure type

• Smothers fire with layer of powder
• Use on Class A, B and C fire

Chemical Foam • Aqueous film forming foam (AFFF) type

• Smothers fire with foam
• Use on class A and B fires

क े ड गैस • Halon, CO2 type

• Smothers fire with gas
• Use on Class B and C fies

Table 2.2.2 Types of fire ex nguisher

Colour Codifica on of Fire Ex nguishers

Type Old Code BS EN 3 Colour Code Fire Class

Water Signal Red Signal Red A

Water Mist White and Red White and Red A (B, C, electrical if
Dielectrically tested)

Foam Cream Red with a cream A and B

panel above the
opera ng instruments

Dry Powder French Blue Red with a cream

panel above the
Opera ng instruments

Carbon Dioxide Red with a cream A

panel above the
Opera ng instruments

Halon No longer prodiced - A

Illegal in the UK

Wet Chemical Not in use Red with a cream A

panel above the
Opera ng instruments

Table 2.2.3 Color coding of fire ex nguisher

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Steps for using a fire-ex nguisher

Pull The Pin Aim at the Base of Fire

Squeeze the Liver Sweep side to side

Fig: 2.2.3 Using a fire ex nguisher

2.2.5 Emergency Procedures

Every workplace should have a plan for dealing with emergencies. You should be instructed in that plan
within your first few days on the job and have refresher training from me to me. Once you have been
trained, you should be able to answer these ques ons during an emergency:
Ÿ Where the emergency phone numbers are posted?
Ÿ Where are the fire ex nguishers and how and when should they be used?
Ÿ What other specialized equipment may be needed in an emergency, and how it is used?
Ÿ Where are the fire alarms and fire exits?
Ÿ What is the evacua on plan for the building?

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 Electric Vehicle Service Technician

Ÿ What should you do during an earthquake?

Ÿ In case of evacua on, where outside the building is the assembly point and who should you report
to?
Emergency Service Number
Dial the service number of these departments in case of emergency:
Ÿ Fire Brigade Department
Ÿ Police Department
Ÿ Ambulance Department
Ÿ Women Safety Department
Ÿ Security Department
Fig: 2.2.4 Emergency service number
Ÿ Pest Control Department
Medical Emergency Procedures
Follow these steps for medical emergency procedures:
Ÿ An emergency medical service should be available near to your dealership
Ÿ At least one person should be trained enough to handle any medical emergency
Ÿ First-aid supplies should be available at the dealership
Ÿ Check - Call - Care route should be followed

Fig: 2.2.5 Medical emergency procedure

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2.2.6 Evacua on Procedures for Workers & Visitors

Let’s now learn about the for evacua on procedures for workers & visitors in case of emergency.
As the first step a layout must be made of the building, including:
Let’s now learn about the for evacua on procedures for workers & visitors in case of emergency.
As the first step a layout must be made of the building, including:
Ÿ Evacua on Routes
Ÿ Fire Ex nguisher (loca ons)
Ÿ Fire Alarm Sta ons (loca ons)
Ÿ First Aid Kit (loca ons)
The second step for evacua on procedures for workers & visitors in case of emergency includes a map of
the building, parking, area and other buildings surroundings.
This must show the Rally Point. Rally Point must be a safe distance from the building. It must be easily
accessible, out of the way of emergency services, and should not be beside the fire hydrant. Both the
layout and the Rally Point must be posted no ceably throughout the facility and made accessible to all
employees upon request.

Fig: 2.2.6 Sample evacua on plan

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 Electric Vehicle Service Technician

2.2.7 Procedure for Repor ng and Responding

to Accidents and Other Emergencies
Ÿ One of the essen al responsibili es of an individual is repor ng hazards for electrical works. He
should be aware of:
Ÿ the people responsible for health and safety at the work place;
Ÿ the name, designa on and loca on of the person responsible to contact at the me of emergency;
Ÿ the names and loca on of the documents that refer to health and safety in the workplace.
Addi onally, an individual should also be adept in wri ng accident report. An accident report needs to
include all the essen al informa on about the incident or near-miss. The report-wri ng process begins
with facts and ends with recommenda ons for preven ng future accidents.
Accident report involves four steps:
1. Gathering Facts: Collect and note all the facts, including -
Ÿ Date, me, and loca on of accident
Ÿ Names, job tles, workers and immediate supervisor involved
Ÿ Events leading up to the accident
Ÿ Job that a worker was handling at the me of the accident
Ÿ Names of workers/supervisor who witnessed the accident
Ÿ Surrounding condi ons (e.g. greasy floor, insufficient ligh ng, noise, etc.)
Ÿ Circumstances at the me of accident (including tasks, equipment, tools, materials, etc.)
Ÿ PPE worn by the worker at the me of the accident
Ÿ Injuries that occurred (name of the injured body part and characteris cs and extent of injuries)
Ÿ Type of treatment for injuries (first aid if given)
Ÿ Damage to equipment, materials, and the worker was working on or any other equipment or
material around it.
2. Determining the Sequence: Describe this sequence in events a er gathering the facts -
Ÿ Events leading up to the accident: Task the worker was performing at the me of accident. For
example: bending over, climbing, li ing opera ng machinery, using a tool, handling hazardous
materials, etc.
Ÿ Events involved in the accident: Was the employee struck/caught in the machine or caught in
the fire? Did the worker fall on the same level or from a height? Did he inhale hazardous fumes
or get splashed with a hazardous chemical?
Ÿ Events immediately following the accident: What did the employee do: started bleeding? Body
caught fire? Complain about back pain? Put a hand over a bleeding wound? Response From
other workers/supervisor. Did they call for help, administer first aid, shut down equipment,
move the vic m to the other place, etc.?
The accident should be described on the report in sufficient detail that any reader can clearly
picture what happened. A picture can also be drawn, in a simple and visually effec ve manner,
the sequence of events related to the incident and include this in your incident report. Photos
can be clicked by the mobile phone of the accident scene, injury the occurred which may help
reader follow the sequence of events.

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3. Analysing: Analyse of the causes of the accident. Causes include:

Ÿ Primary cause (e.g., a slip and fall from a ladder)
Ÿ Secondary causes (e.g., employee not wearing appropriate goggles or helmet)
Ÿ Other contribu ng factors (e.g., poor ven la on).
4. Recommending: Recommenda ons for correc ve ac on might include immediate as well as long-
term correc ve ac ons such as -
Ÿ Training on safe work prac ces
Ÿ Preven ve maintenance exercises that keep equipment in great working condi on
Ÿ Assessment of job techniques with a proposal for changes
Ÿ Conduc ng a job hazard analysis to evaluate the task for any other hazards and then train
employees on these hazards
Ÿ Engineering changes that make the task safer or administra ve changes that might include
changing the way the task is performed

2.2.8 Basic First-aid Techniques

Free a person from electrocu on
If find someone is suffering from electric shock,
approach with extreme cau on and following first
aid steps.
Steps
1. Firstly take the suffered person away from the
electricity source as fast as possible. Turning
off the electric supply of machine is the best
method for doing this.
2. If this seems impossible, remove the person
from electricity source by using a piece of
wood or insula ng material.
3. Don’t touch the vic m ge ng the electric
shock because you could also get shock too.
Fig: 2.2.7 Saving person from electrocu on
4. A er successful execu ng the vic m from the
electricity source, call the ambulance, if vic m is
unconscious. Give first-aid to vic m ll the me ambulance is coming.
5. If vic m is conscious and looking well, monitor its condi on, as the results of shock must not be clear
immediately.

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 Electric Vehicle Service Technician

2.2.8.1 First-aid in Case of Bleeding, Burns, Choking, Electric

Shock, Poisoning etc.
For trea ng shock, burns, bleeding and wounds, electric shock, choking, eye injury, heat stroke,
hypothermia, fain ng and unconsciousness, use following first-aid techniques:
Shock
Cold, weakness, unbalanced breathing, rapid weak pulse, pale or bluish lips and fingernails and nausea
are the symptoms of shock.
Steps
1. Don’t give anything for ea ng and drinking to vic m.
2. Put down the vic m on his/her back. Don’t move the vic m if there’s any neck or back injury. If find
vic m is unconscious or vomi ng, put down on his/her side and ensure that sufficient air is
available in the room.
3. Use blankets or clothes to keep the vic m warm.
4. Place the vic m’s legs on a pillow.
Bleeding and Wounds
Steps
1. Cover the wound by a clean cloth and gloved hand; then apply firm and steady pressure on wound
for 5 mins at least.
2. Li up the injured leg or arm above the vic m’s heart level.
3. Secure the wound by a bandage when bleeding stops. Ensure that bandage is not fixed too
ghtly—it may stops blood circula on.
4. Check the vic m for shock.
Burns

Fig: 2.2.8 Saving from gas burns

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Par cipant Handbook

Steps
Chemical or Compressed Gas Burns
1. Use a drench hose and emergency shower for at least 15 mins to rinse away all residues of
chemicals.
2. Cover the burn by a clean and dry cloth or special dressing for burns.
3. Check the vic m for shock.
Heat or Electrical Burns
1. Cool burning of skin by water.
2. Place the burned area under cold running water if the skin is not broken and gently compress the
wound by hand. Bandage the wound by a dry and clean cloth.
3. If blister appear, don’t try to break it.
4. Do not apply ointments or creams.
5. If skin is cracked, or if injuries are severe:
Ÿ Do not clean the wound or remove embedded clothing.
Ÿ Cover the injury insecurely with a clean, dry cloth.
Ÿ Expect shock and treat accordingly.
Choking
The pa ent is talking and ge ng sufficient air; don’t restrict it if he/she
tries to cough the obstruc on in the throat. If the pa ent can’t talk or not
ge ng enough air, make call on emergency number.
Steps
1. Wrap your arms around the stomach and stand directly behind the
vic m.
2. Just above the navel and well below the ribs, make a fist by a hand.
Place that fist with the thumb and forefinger side toward you.
3. Hold the fist by other hand and pull it rapidly towards you by a
Fig: 2.2.9 Saving person
slightly upward and inward thrust. If required, repeat it. from choking
If the pa ent becomes insen ent:
1. Put down the pa ent on their back.
2. If the object that is obstruct the airway is no ceable, reach a finger
into the pa ent’s mouth and try to bend the obstruc on out of the
pa ent’s throat, being careful not to push the object deeper into the
pa ent airway.
3. Even if this is not successful, a empt rescue breathing.
4. A chest compression (CPR) is more helpful if the vic m is s ll not
Fig: 2.2.10 Saving person
breathing or moving. from choking

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 Electric Vehicle Service Technician

2.2.8.2 Basic Techniques of Bandaging

The key points when applying a bandage are:
Steps
1. Make sure the person is comfortable.
2. Never lean across their body and ensure that you are
working from the side of the injury.
3. First clean the wound and apply the an bacterial cream
over it.
4. When the bandage is on always remember keep the
injured part of the body supported in the posi on it will Fig: 2.2.11 Bandaging injured person
be in.
5. Always use right size of bandage.
6. To check the passage easily, don’t cover fingers or toes when bandaging a limb.
7. Never wrap the bandage ght, and secure the end by folding it over and binding a knot in the end.
Safety pin, adhesive tape, or a bandage clip can be used.
Ar ficial respira on and CPR Process
CPR instruc ons
Ÿ Check the Passage - make sure it is harmless for you to help.
Ÿ Don’t become another pa ent.
CPR Steps

1. Check the Vic m - tap and shout to get response.

2. Circula on - pump the chest 30 mes.
3. At the center of the chest put the heel of one hand and your other hand on top of it. At a rate of 100
per minute (16 compressions in 10 seconds) press chest down 2 inches.
4. Tilt head back, li chin up to open airway - Airway.
5. Breathing - Tweak nose closed, take a normal breath, cover pa ent mouth with yours and blow out
your breath un l you see the chest rise. One breath per 1 second. Again open airway again if chest
doesn’t rise.
6. Repeat procedure un l help arrives or the vic m begins breathing.

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Par cipant Handbook

2.2.8.3 Correct Method to Move Injured People

and Others During an Emergency
To carry injured people to medical help or rescue from further harm. In these cases, you must consider
the number of rescuers you have, the capabili es of these rescuers and the condi on of the pa ent that
must be s mulated. Below discussion on several ways to carry an injured person:
Steps
1. Stand on either side of the conscious vic m. Grab the vic m’s wrist
with the hand closest to the vic m’s feet on your side.
2. Use your other hand to grasp the clothing on the shoulder nearest to
you and pull the vic m’s arms to help them to a si ng posi on.
3. Assist the vic m to his or her feet and place the arms around your
shoulders, if possible.
4. Place your free hand around the person’s waist and let him or her set
the pace on hobbling out.
5. Help the vic m for moving slowly.

Fig: 2.2.13 Moving injured people

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 Electric Vehicle Service Technician

Unit 2.3 - Workplace Quality Standards

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. State the methods to keep the work area clean and dy
2. Apply basic housekeeping prac ces to ensure that the work area is clean, such as mopping spills and
leaks, cleaning grease stains etc
3. Perform rou ne cleaning of tools, equipment and machines
4. Discuss how to complete the given work within the s pulated me period
5. Discuss ways to maintain a proper balance between team and individual goals

2.3.1 Housekeeping Prac ces

Housekeeping in simple words means maintaining a house on a daily or long term basis or looking a er
its cleanliness, diness, upkeep and smooth running.
Cleanliness doesn’t mean housekeeping. Housekeeping includes keeping work areas dy and arranged;
keep floors free of slip and trip accidents; clearing of waste materials (paper, cardboard) and other fire
hazards.
Workplaces hazards can be eliminate by effec ve housekeeping and complete a job safely and properly.
Poor housekeeping and hiding hazards can cause frequent accidents which can cause injuries.

2.3.1.1 Principle of Workplace Housekeeping

Housekeeping consists of the simpler aspects of care and maintenance of workplace and its associated
items:
Ÿ Maintaining opera onal diness and order,
Ÿ Properly controlling waste, and
Ÿ Regula ng ac vi es such as smoking that can lead to hazardous condi ons.
Good housekeeping is a vital factor in preven ng accidents. The great majority of all work accidents are
caused during the handling of goods or materials, and by people falling, being hit by falling objects, or
striking against objects in the workplace. All these causes can be reduced by good housekeeping
prac ces—in fact, good housekeeping is the only cure for hundreds of accidents that occur.
Here are some kinds of accidents commonly caused by poor housekeeping:
Ÿ Tripping over loose objects on floors, stairs and pla orms.
Ÿ Ar cles dropping from above.

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Ÿ Slipping on greasy, wet or dirty surfaces.

Ÿ Striking against projec ng, poorly stacked, or misplaced material.
Ÿ Tearing the hands or other parts of the body on projec ng nails, wire, steel strapping on bales or
Crates, etc.
Typical examples of poor housekeeping that lead to these accidents are:
Ÿ Excessive material, waste or chips in the working area.
Ÿ Congested aisles.
Ÿ Tools le on machines.
Ÿ Waste containers overflowing.
Ÿ Lockers and workrooms in disorder.
Ÿ Acids in open containers.
Ÿ Broken glass.
Ÿ Electric leads or air lines across aisles.
Ÿ Dirty light fi ngs, windows and skylights.
Ÿ Un dy or dangerous storage of materials (e.g., materials stuffed in corners, overcrowded shelves,
etc.)
Ÿ Dusty, dirty floors and work surfaces
Ÿ Spills and leaks
Where housekeeping is bad, fire is a constant hazard. It can be caused by many housekeeping
problems— such as oil-soaked rags and clothing igni ng from spontaneous combus on; dust collectors
not being properly or frequently cleaned; or piles of paper and other packing materials being allowed to
accumulate.

2.3.1.2 Benefits of Good Housekeeping Prac ces

Efficient housekeeping results in:
Ÿ Decrease handling to comfort the materials flow
Ÿ Fewer slipping and tripping accidents
Ÿ Less fire hazards
Ÿ Be er control of tools and materials in managing inventory and supplies
Ÿ Equipment’s are more cleaned and well maintained.
Ÿ Be er hygienic condi ons for good health
Ÿ Space u liza on is more efficient
Ÿ Reduced property damage due to improvement in preven ve maintenance
Ÿ Improved efficiency because it is easy to find tools and materials.

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2.3.1.3 Good Housekeeping Checklist

Check off your housekeeping programme against this checklist. Be er s ll, make a more comprehensive
list of your own.
Buildings
1. Walls clean.
2. Windows clean.
3. Walls free of unnecessary hangings.
4. Proper light provided.
5. Pla orms in good condi on.
6. Stairs clean and well lit. Handrails and steps of sound construc on and
well maintained.
Floors
1. Good floor surface.
2. Kept clean and free of loose material. Clean in corners, behind radiators,
along walls, and around pillars or columns.
3. Free of oil, grease, etc.
4. Opera ng floors, or work posi ons free of loose scrap, metal or other
materials.
5. Free of unnecessary ar cles.
6. Bins provided for refuse.
Fig: 2.3.1 Waste storage
Aisles
1. Free of obstruc ons.
2. Safe and free passage to fire-figh ng equipment and fire exits.
3. Safe and free access to work posi ons.
4. Clearly defined.
Machinery and equipment
1. Clean and free of unnecessary material.
2. Free of unnecessary dripping of oil or grease.
Fig: 2.3.2 First-aid box
3. Area around machines clean and free of rags, paper, etc.
4. Lockers and cupboards clean and free of unnecessary material both on top
and inside.
5. Benches and seats clean and in good condi on.
6. Drinking fountains clean.
7. Toilet facili es clean and well ven lated.
8. Proper guards provided and in good condi on.
Fig: 2.3.3 Material handling
9. First-aid facili es and equipment fully stocked and in clean condi on.

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Par cipant Handbook

Stock and material

1. Properly piled and arranged
2. Kept in storage areas.
Tools
1. Properly arranged in place.
2. Free of oil and grease.
3. Inspected and maintained in good order.
4. Tool rooms and racks in clean and orderly condi on. Fig: 2.3.4 Tools placement
Grounds
1. Yard and building surrounds free of refuse such as fruit peelings,
scrap, wood, Iron, etc.
2. Grounds kept free of weeds and overgrown vegeta on.
3. Wastes and refuse removed frequently.
Good housekeeping helps to create:
• Be er working condi ons
• Safer workplaces
• Greater efficiency.
It is not an unprofitable sideline. It is part of a good business. Fig: 2.3.5 Floor cleaning

Waste Disposal

Fig: 2.3.6 Waste disposal

Prac ces the regular collec on, grading and sor ng of scrap leads to good housekeeping. Separate the
materials from waste which can be recycled and reuse.
For systema c waste gathering and disposal, place the bin containers, near the place where waste is
generated most.

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 Electric Vehicle Service Technician

2.3.2 Work In Line with Organiza on Policies & Procedures

Organiza ons will have a set of rules that direct employees’ ac on in accordance to what is believed to
be right. One should follow the policies set by the organiza on.
The meaning of working ethically means you should be on pre-define shi me, should take leave when
you are sick, not using the telephone for personal purpose, avoid gi from customers, should not use
anything belong to customer, should not indulge in gossiping about others behind them, showing
support to other workers and keeping client informa on confiden al. In the workplace it is important to
always behave in an appropriate way and report any problems to your supervisor.

2.3.3 Time Management

We achieve outcome of our 24 hours period based on our enthusiasm, energy levels, ability to perform,
skills and other resources
As our me is always in demand, we need to think about how to use our me and for more effec ve me
management we need to consider certain strategies. Time management does not mean to work harder
or for longer period but it help us to work smartly so that we can finish our work easily and quickly.

Fig: 2.3.7 Time management

If we can manage our me more effec vely, we will be rewarded in a variety of ways:
Ÿ We will be more competent in our rou ne job and also can support others
Ÿ We can accomplish great success in every role as a leader
Ÿ On a personal level, you will certainly feel healthier, more energe c, and in a generally be er mood.

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2.3.3.1 Obstacles to Effec ve Time Management

There are many factors contribu ng to disturbance due to which it becomes for us in effec ve
management of our me. Now think about certain common factors, and let us see does it apply to us:
Ÿ Objec ve is not clear - With closed eyes it is difficult to hit a target thus it is equally difficult to
accomplish something when you aren’t exactly clear about what you want to achieve.
Ÿ Disorganiza on - It’s easy to see when your desk is too messy, but some mes you have to step back
and ask yourself if you are taking an organized approach in comple ng all of your tasks.
Ÿ Inability to Say “No” - We need to be helpful; towards others when they need our support, but this
needs me and could result in disturbing our priori es to do something we may not have planned.
Ÿ Interrup ons - Some me it happens that when are in the middle of accomplishing something which
is very important for, we get a phone call. These calls are very disturbing as it could play an import
reason to be behind the schedule as it may interrupt our though process which can lead to go back
from where we started or in between somewhere.
Ÿ More Interrup ons - Inappropriate me conversa ons need our me thus we need to be careful and
have to stop what we are doing and focus on plans.
Ÿ Periods of Inac vity - As much as we think we are busy, there are mes in our day when we are not
really doing anything. Recognizing and making use of these mes can have a posi ve effect on our
efforts.
Ÿ Too Many Things at Once - Most of us work without making rou ne of our task as it needs our
en on for detailing. When we try to do so many things simultaneously each individual task get
suffer.
Ÿ Stress and Fa gue - We all experience stress me to me in our daily life and we perform well with a
li le bit stress. If the level of stress is very high, our works get suffered and also effect mental and
physical situa on. How to deal with stress forms an important factor of me management.
Ÿ All Work and No Play - Most successful people know how to balance work and play. When work takes
over your life, you may end up sacrificing the really important things in life like family and friends.
Therefore, give your body li le me to re-energize and enjoy life.
Ac vity
Ÿ Collect the three pages containing 24 squares on them from your facilitator.
Ÿ Fill the squares (based on the me you spend on various ac vi es on a regular day) and label them
with rou ne ac vi es like:
} Sleeping (6 hours is equal to 6 squares), bathing, ea ng, travel, and TV me
} Non-reproduc ve me like long tea-breaks, water cooler chats, personal telephone calls and e-
mails, etc.
Ÿ Produc ve me like reading something useful or brainstorming on important topic
Ÿ A er filling all squares, iden fy me wasters and me spent on rou ne ac vi es.
Ÿ Come up with as many ideas as possible to handle your me wasters.
Ÿ Share your findings with your facilitator in the next session.

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 Electric Vehicle Service Technician

2.3.3.2 Resolving Obstacles

The obstacle we face in our day to day life is not very difficult to resolve. The most important thing is to
iden fy existence of obstacle which is affec ng our ability in me management. A er iden fying the
obstacle we start think solu on to resolve it.

2.3.4 Set Clear Goals

Ÿ You will want to accomplish many things in your me of office. The greatest favor that you can do to
yourself is to define what those targets are and ensure your struggles are always absorbed toward
their accomplishment.
Ÿ Effec ve goals share a number of characteris cs in common. Effec ve goals are:
} Specific - When a goal is too vague, you may never know how to grasp it or even when you have
reached it. Ensure that you know exactly what you hope to achieve.
} Measurable - When you have a goal that is measurable, you will know how far you have to go to
reach the goal, and when you will get there.
} Achievable - It is worthy to set your vision high, but some mes we try to achieve more than we
can actually do. Your goals should be such that, if you “extend yourself” you can just reach them.
For example, if a person weighing 100 kilos decides to lose 30 kilos in a month its absurd. Rather if
he set a goal to lose 5 kilos each month that’s achievable.
} Realis c - Your goal has to be real. Saying I will fetch the moon for you, as in many Bollywood
movies is fic ous. So set your goal that is realis c. You can refer to the same example of a person
weighing 100 kilos. If he wants to build body like John Abraham or Hri k Roshan in a month it’s
unrealis c.
} Time-based - It is important to set me guidelines for your goals, so that you can keep track of
your development as you are along and can be aware to when you are falling behind The
schedule.

S M A R T
Specific Measurable Achievable Relevant Time-bound

Provide a clear Include a metric Set a challenging Keep your goal Set a date for
descrip on of with a target target, bt keep it consistent with when your goal
what needs to that indicates Realis c. highter-level needs to be
be achieved. sucess. goals. achieved.

Fig: 2.3.8 SMART Goals

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2.3.5 Priori ze
As a part of organiza on, you will be assigned many tasks. It is always good and safe to clarify that you
cannot do everything, thus it is important to make a list of tasks periodically that confront you and
priori ze them. Below men oned technique may help in priori zing:
Ÿ Do - Choose most important task from the list which you consider as important for your organiza on.
These are the task you need to do yourself.
Ÿ Delegate - There could be many persons in an organiza on who possess various skills and experience
to carryout variety of task. A real leader understand it very clearly that they cannot accomplish
everything by themselves. Thus they recognize someone who can be er handle the task. Delega ng
not only helps to free up your me so that we can do other works but also ensures resources applied
can be used more effec vely through certain degree of mo va on.
Ÿ Delay Un l another Time - As a regular process we think something can wait and applying same
thinking on too many things close to the dead line which creates a dangerous situa on. It is always
good to consider when things are due, how long it will take to accomplish and your current workload.
Suppose you have to pay for your policy but s ll have me you can delay it but when it comes to
deadline it may hamper your working process.
Ÿ Delete - If we set our goals as explained earlier, we will experience that some of these goals are not
achievable or realis c, or that they are just not important. A good leader knows when to concentrate
on the important and eliminate the rest.
When you priori zed your task it is important for you to:
Ÿ Address the Urgent - Things having short-term consequences should be tackled first.
Ÿ Accomplish What You can Early - Reports, registra ons and requests that can be handled early
should come next. Don’t put off un l tomorrow what you can do today.
Ÿ A ach Deadlines to Things You Delay - A aching deadlines to things we delayed - When we are very
sure that things can definitely wait be careful in taking such decision by adding a deadline for that task
in our schedule and should also make a note to remind our self about when we should start working
on that.

URGENT & IMPORTENT NOT

IMPORTENT URGENT
secide when to
do it now do it

URGENT NOT NOT IMPORTENT

IMPORTENT NOT URGENT
delegate it delete it

Fig: 2.3.9 Priori zing work

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2.3.6 Organize
As you priori ze tasks and set deadlines,
you will want to organize your plans and
ac ons. Some me we are using paper
and pencil to organize our plans, but it is
My To-Do List
i m p o r t a n t f o r y o u i n t o d a y ’s Date Item
environment to use planner as it includes
calendar and enough space to make
notes. Most of the planners are
equipped with calendar space, space to
note down daily ac vi es, contact
informa on, and “to do” lists. Look for
the planner which sa sfy your need and
start using it. You will feel like it is an
essen al tool for you to manage your
me.
We can also consider device like Fig: 2.3.10 To-do list
computer to help in organizing our me.
The modern computers are equipped
with necessary features such as calendars, task lists,
reminder, and contact details using so ware programs. In case you do not have these features in your
computer you get it installed very easily.
You may also consider a small personal digital assistant, or PDA. These devices are small enough to fit in
your hand, and use the same so ware your home computer uses. When we do not have computer
access PDAs plays important role specially during travelling to keep you updated with your pending task.
Whatever method you choose, make sure you organize your tasks so that you can stay on track.

2.3.7 Focus on the Task

When you serve as a leader you are managing many ac vi es and we cannot cut ourselves from this fact.
There is no way around this fact. But, one important strategy to keep in mind is to concentrate
completely on the current task. Concentra on can be difficult when you have a lot on your mind. Your
me will be be er spent if you are able to:
Ÿ Focus on Your Goal - Everybody has various set of commitments and concerns, but for be er
accomplishment focus on the task at a moment is very much required.
Ÿ Avoid Interrup ons - When need to set our specific me in day me in which we should not talk on
phone or a end visitor mee ng because this is the me we can pay highest level of a en on to our
task. We cannot separate all of our me but definitely avoid interrup on during specific period of
me and this way we can successfully complete task in less me than it was expected. When you
must respond to phone calls, be asser ve in minimizing interrup ons by asking if you can call back at
another me or meet another day.

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2.3.8 Working in Team

Lessons from the Geese :
Teams are much more effec ve than individuals for work. Let’s look at an example from Mother Nature
to learn how an effec ve team works.
The geese actually fly in a group on their long flight of migra on.
The flapping of the geese that are in front of the forma on creates a dra for the geese at the rear
reducing air resistance. This indicates their true sense of responsibility towards the fellow beings.
When the leader goose is red, it goes back and another goose then comes in the front to lead the group
of Geese. So, these Geese have no fixed leadership or hierarchy. No goose likes to fly out of forma on
because it would get red easily. Even if it does fly out of forma on, it quickly comes back to its place. So,
Geese have amazing team sense!
Geese also make a lot of noise while they fly. But it’s interes ng to note that the noise is not made by the
geese leading the forma on, but by the Geese in the back of the forma on, which serve to support and
keep everyone going. Isn’t that the unique vocal support?
If one goose is ill and falls out of forma on, a few of others stay with it, to be with it un l it gets well or
dies. Now, that’s what we call team spirit!
Geese are unique as a team. The team works on a common goal and are cohesive in nature to reach their
des na on. Team members help each other since they can collec vely achieve much more than they
can alone.
As explained about the Geese, being a human if we are sharing common set of direc on and have
consider our community can move fast and reach to our goal in shorter period because we move with
trust on each other.
Considering the Geese if we follow their footsteps we will be connected with the persons who could lead
us to reach our des na on.
We willing accept help from others and offer our help to others.
It pays to take turns in doing the hard tasks and share the leadership. As with Geese, people are
interdependent on each other’s skills, capabili es and unique arrangements of gi s, talents and
resources.
We need to ensure we are encouraging each other in the team. In teams where there is encouragement,
the produc on is much higher. If we have to learn from Geese, it is to stand by each other in tuff mes as
well as good mes. Now, what do you say to that!!!
You need to be a good team player to work in a team.
Commitment & Task Sharing Based on Individual’s Skills
A commi ed team treats the work like their own garden or pet - they obsess over it, they care for it, they
own it. If a leader is trying to build a team who can give commitment to finish the assigned task, then it is
important to align team member’s personal visions to that of the organiza on.

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2.3.8.1 Resolving Conflict

Conflict - It can be defined as a serious disagreement or argument. Conflict exist in almost all
organiza on and some me it is also consider posi ve as it helps in healthy exchange of ideas and
crea vity. If the conflicts became counter conflict it may leads dissa sfac on to employee, produc vity
reduc on
Importance of Resolving Conflict:
You must avoid conflict at the work place as it brings nega vity all around.
By deciding not to say something that would make you sound aggressive or frustrated, you can avoid
unnecessary conflicts.
Conflicts take place when people are rigid and are not willing to cooperate with each other. Let’s look at
some ways through which you can prevent and resolve conflicts.
Best Prac ces Resolving Conflict:
To resolve conflicts in a team, you should use these steps:
Ÿ Examine what is causing trouble
Ÿ Discuss the issue with the conflic ng party
Ÿ Clarify expecta ons and roles
Ÿ Find an op on which benefits all
Ÿ U lize construc ve feedback
Ÿ Reach agreements
You should always maintain a posi ve rela onship while trying to reach an agreement.
Depersonalizing Conflicts:
You should always depersonalize conflicts by adop ng these steps:
Ÿ Focus on issues not personali es
Ÿ Encourage both sides to be objec ve
Ÿ Evaluate concerns of both sides
Ÿ Encourage people to listen to other’s view
Ÿ Encourage points of agreement
Ÿ Don’t dwell on anger
When individuals find it difficult to adjust with each other, the best way is to sit together and
discussamong themselves to reach the middle path. Instead of figh ng with each other, it is be er to
discuss things and come to a solu on which benefits all. For example, when the boss sets the meline for
comple ng a given task and the team member finds it unachievable, the team member should nego ate
with his boss to slightly extend the meline to make it prac cally achievable. Through discussion they
can then reach the meline that suits all.
Resolving Complaints:
Use the following do’s to resolve complaints:
Ÿ Be warm to the others
Ÿ Show empathy

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Ÿ Acknowledge the other’s feelings

Ÿ Listen ac vely
Ÿ Isolate the core problem
Ÿ Provide a sa sfactory resolu on and an alterna ve
Ÿ Follow-up a er the resolu on
Avoid the following don’ts to resolve complaints.
Don’t:
Ÿ Take a confronta onal a tude
Ÿ Make assump ons
Ÿ Use technical or professional jargon
Ÿ Pass the blame
Ÿ Make unrealis c commitments
Ÿ Exceed your authority
Ÿ Sacrifice your company’s interest
Responding to a Transac onal Crisis:
Use the following do’s to respond to a Transac onal Crisis:
Ÿ Tell the whole story:
} Openly
} Completely
} Honestly
Ÿ Apologize, if you are at fault
Ÿ Show your concern with:
} Words
} Ac ons
Avoid the following don’ts to respond to a Transac onal Crisis.
Don’t:
Ÿ Blame others
Ÿ Speculate in public
Ÿ Refuse to answer ques ons
Ÿ Release confiden al informa on without permission
Ÿ Use the crisis to promote yourself

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Notes
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Par cipant Handbook

Unit 2.4 - Health and Hygiene During an Epidemic and

Pandemic

Unit Objec ves

At the end of this unit, the trainee will be able to:
1. Discuss epidemics and pandemics and their impact on society at large
2. Elaborate the significance of following prescribed rules and guidelines during an epidemic or a
pandemic
3. Discuss the significance of conforming to basic hygiene prac ces such as washing hands, using
alcohol-based hand sani zers
4. Show how to sani ze and disinfect one’s work area regularly
5. Demonstrate the correct way of washing hands using soap and water
6. Demonstrate the correct way of sani zing hands
7. Demonstrate appropriate social and behavioural e que e (gree ng and mee ng people, spi ng/
coughing/sneezing, etc.)
8. Discuss the ways of dealing with stress and anxiety during an epidemic or a pandemic

2.4.1 Safety During Epidemics and Pandemics

Difference between epidemic and pandemic
Ÿ An epidemic is a disease that affects a large number of people within a community, popula on, or
region.
Ÿ A pandemic is an epidemic that’s spread over mul ple countries or con nents.
An epidemic can provoked social s gma and discriminatory behaviours against people of certain ethnic
backgrounds as well as anyone perceived to have been in contact with the virus.
The level of s gma associated with an epidemic is based on three main factors:
1. it is a disease that’s new and for which there are s ll many unknowns;
2. we are o en afraid of the unknown; and
3. it is easy to associate that fear with ‘others’.
It is understandable that there is confusion, anxiety, and fear among the public. Unfortunately, these
factors are also fueling harmful stereotypes.
WHAT IS THE IMPACT?
S gma can undermine social cohesion and prompt possible social isola on of groups, which might
contribute to a situa on where the virus is more, not less, likely to spread. This can result in more severe
health problems and difficul es controlling a disease outbreak.

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S gma can:
Ÿ Drive people to hide the illness to avoid discrimina on
Ÿ Prevent people from seeking health care immediately
Ÿ Discourage them from adop ng healthy behaviours

2.4.2 Safety Protocols During Epidemics and Pandemics

Follow these safety protocols during an epidemic to keep yourself and others safe:

Fig: 2.4.1 Safety protocols during epidemic

1. Wash your hands o en with soap and water, especially a er being in a public place, or a er blowing
your nose, coughing or sneezing.
Ÿ If soap and water are not readily available, use a hand sani zer with alcohol.
Ÿ Avoid touching your eyes, nose and mouth with unwashed hands.

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2. Avoid close contact with people who are sick. Some people without symptoms may be able to
spread the virus.
Ÿ Stay home as much as possible and avoid non-essen al travel.
Ÿ Prac ce social distancing by keeping at least 2 meter — about two arm lengths — away from
others.
3. Cover your mouth and nose with a cloth face cover when around others. The cloth face cover is
meant to protect other people in case you are infected.
4. Cover your coughs and sneezes. Use a ssue to cover your nose and mouth, and throw used ssues
in a lined trash can. If a ssue isn’t available, cough or sneeze into your elbow — not your hands.
Wash your hands immediately.
5. Clean and disinfect frequently touched surfaces daily. This includes tables, tools, machines switches,
countertops, handles, desks, phones, keyboards, toilets, faucets and sinks.
IF YOU ARE SICK
Ÿ Stay home and call doctor for medical advice.
Ÿ Separate or isolate yourself from other people in your home.
Ÿ Avoid sharing personal items, with others.
Ÿ Clean and disinfect high-touch surfaces daily.
Ÿ Wear acloth face cover if you are around other people.

2.4.3 Workplace Hygiene

All workplace environments need to be hygienic and safe for both employees and visitors. This applies to
all, not just workplaces involved in handling food and personal products.
A solid workplace hygiene policy is the best way to ensure employees maintain a clean workplace.
Each workplace will require different hygiene requirements. Certain tasks, or industries may also create
risks which require addi onal protec on than those discussed below. However, below are some key
areas all workplaces should consider for their workplace hygiene policy.
Why Is Hygiene Important in the Workplace?
Hygiene is important in the workplace because it contributes to a healthy workforce. A healthy
workforce is happier and more produc ve. A healthy workplace also means workers take less sick leave.
Which will reduce the huge cost that sick leave places on small business.
How do you maintain hygiene in the workplace?
Implement a hygiene policy
Provide staff with a wri en hygiene policy. Inform them of your inten ons and expecta ons of a clean
workplace. This helps communicate to staff that you also take workplace hygiene seriously.

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Provide a clean bathroom

It is pivotal for a hygienic workplace to have a clean bathroom. Also ensure that the bathroom is well
stocked with soap, toilet paper and hand towels.
Provide clean wipes, sani ser and ssues
Provide items such as these to help your staff maintain a clean and hygienic workspace. Employees are
more likely to use such items if they are readily available.
Regular cleaning
Make sure your workplace is regularly cleaned. This helps prevent the spread of infec on, and a cleaned
workplace also maintains morale and a sense of professionalism.
What Is the Basic Hygiene in a Workplace?
Basic hygiene in the workplace can be put down to four different things: personal hygiene; work area
cleanliness; clean restroom facili es; and a clean kitchen.
Why Is Personal Hygiene Important in the Workplace?
Personal hygiene refers to the cleanliness, appearance and habits of employees. Personal hygiene of
employees, for obvious reasons, can be a sensi ve issue for business owners.
A well-groomed personality projects a good image and speaks well of hygiene and efficiency. As far as
possible, personnel should —

TAKE SHOWER SHACE YOUR FACIAL AVOID SMOKING

EVERYDAY HAIR REGULARLY DURING OFFICE
HOURS

APPLY DEODRANT BRUSH YOUR RINSE EVERY TIME

TO PREVENT TEETH AFTER EATING
BODY ODOUR TWICE EVERYDAY

Fig: 2.4.2 Personal hygiene

Ÿ be fresh, well-groomed and clean, not half asleep or unkempt in appearance while repor ng on duty
Ÿ have their hair neatly cut and ed properly
Ÿ have nails neatly trimmed

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Ÿ dress in simple, clean and well ironed clothes

Ÿ avoid rings or other jewellery
Ÿ use light makeup, in case of women
Ÿ use footwear that is light, without heels and noiseless
Ÿ be healthy and not suffer from any skin disease, colds, etc.
Ÿ avoid bad habits such as nail bi ng, nose picking, leg shaking, si ng on work table, spi ng, chewing
pan, smoking, etc.
Ÿ bathe daily.

2.4.3 Workplace Hygiene

Cleaning and disinfec ng are part of a broad approach to preven ng infec ous diseases in the
workplace. To help slow the spread, cover coughs and sneezes with your elbow or ssue; wash your
hands, and keep sick people away from others. It is important to make employees aware that if they feel
ill, stay home from work. Below are ps on how to slow the spread of germs specifically through cleaning
and disinfec ng.
1. Know the difference between cleaning,
disinfec ng, and sani zing: Cleaning removes
germs, dirt, and impuri es from surfaces or
objects. Cleaning works by using soap (or
detergent) and water to physically remove
germs from surfaces. This process does not
necessarily kill germs, but by removing them, it
lowers their numbers and the risk of spreading
infec on.
Disinfec ng kills germs on surfaces or objects.
Disinfec ng works by using chemicals to kill
Fig: 2.4.3 Sani za on and hygiene
germs on surfaces or objects. This process does
not necessarily clean dirty surfaces or remove germs, but by killing germs on a surface a er cleaning,
it can further lower the risk of spreading infec on.
Sani zing lowers the number of germs on surfaces or objects to a safe level, as judged by public
health standards or requirements. This process works by either cleaning or disinfec ng surfaces or
objects to lower the risk of spreading infec on.
2. Clean and disinfect surfaces and objects that are touched o en: Follow organiza on’s standard
procedures for rou ne cleaning and disinfec ng. Typically, this means daily sani zing surfaces and
objects that are touched o en, such as desks, countertops, doorknobs, computer keyboards, faucet
handles, and phones. Standard procedures o en call for disinfec ng specific areas, like Bathrooms.
Immediately clean surfaces and objects that are visibly soiled. If surfaces or objects are soiled with
body fluids or blood, use gloves and other standard precau ons to avoid coming into contact with the
fluid. Remove the spill, and then clean and disinfect the surface.

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3. Simply do rou ne cleaning and disinfec ng: It’s important to match your cleaning and disinfec ng
ac vi es to the types of germs you want to remove or kill. Most studies have shown that some viruses
can live and poten ally infect a person for only 2 to 8 hours a er being deposited on a surface.
Therefore, it is not necessary to close organiza ons to clean or disinfect every surface in the building
to slow the spread of germs. Also, if employees are dismissed because the organiza on cannot
func on normally (e.g., high absenteeism during a flu outbreak), it is not necessary to do extra
cleaning and disinfec ng.
Some viruses are rela vely fragile, so standard cleaning and disinfec ng prac ces are sufficient to
remove or kill them. Special cleaning and disinfec ng processes, including wiping down walls and
ceilings, frequently using room air deodorizers, and fumiga ng, are not necessary or recommended.
These processes can irritate eyes, noses, throats, and skin; aggravate asthma; and cause other serious
side effects.
4. Clean and disinfect correctly: Always follow label direc ons on cleaning products and disinfectants.
Wash surfaces with a general household cleaner to remove germs. Rinse with water, and follow with
an EPA-registered disinfectant to kill germs. Read the label to make sure it states that EPA has
approved the product for effec veness against specific viruses.
If a surface is not visibly dirty, you can clean it with an EPA-registered product that both cleans
(removes germs) and disinfects (kills germs) instead. Be sure to read the label direc ons carefully, as
there may be a separate procedure for using the product as a cleaner or as a disinfectant. Disinfec on
usually requires the product to remain on the surface for a certain period of me.
Rou nely wash ea ng utensils in a dishwasher or by hand with soap and water. Wash and dry bed
sheets, towels, and other linens as you normally do with household laundry soap, according to the
fabric labels. Ea ng utensils, dishes, and linens used by sick persons do not need to be cleaned
separately, but they should not be shared unless they’ve been washed thoroughly. Wash your hands
with soap and water a er handling soiled dishes and laundry items.
5. Handle waste properly: Follow standard procedures for handling waste, which may include wearing
gloves. Place no-touch waste baskets where they are easy to use. Throw disposable items used to
clean surfaces and items in the trash immediately a er use. Avoid touching used ssues and other
waste when emptying waste baskets. Wash hands with soap and water a er emptying waste baskets
and touching used ssues and similar waste.
Ways to maintain personal sani za on
Maintain social distancing, staying six feet away from
others. Reduce sharing of common spaces and
frequently touched objects.
Ÿ Wear disposable gloves to clean and disinfect and
discard a er use or use reusable gloves that are
dedicated only for cleaning and disinfec ng. Always
wash hands a er removing gloves.
Ÿ Clean any dirty surfaces using soap and water first,
then use disinfectant.
Ÿ Cleaning with soap and water reduces the number of Fig: 2.4.4 Personal sani za on
germs, dirt, and impuri es on the surface. Disinfec ng kills any
remaining germs on surfaces, which further reduces any risk of
spreading infec on.

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} Prac ce rou ne cleaning and disinfec on of frequently touched surfaces. More frequent
cleaning and disinfec on may be required based on level of use.
} Surfaces and objects in public places, such as shopping carts, point of sale keypads, pens,
counters, vending machines, and ATMs should be cleaned and disinfected before each use or as
much as possible.
} Other high touch surfaces include: Tables, doorknobs, light switches, countertops, handles,
desks, phones, keyboards, toilets, faucets, sinks.
When cleaning
Ÿ Wear disposable gloves and gowns for all
tasks in the cleaning process, including
handling trash.
} A d d i o n a l p e rs o n a l p ro t e c v e
equipment (PPE) might be required
based on the cleaning/disinfectant
products being used and whether
there is a risk of splash.
} Gloves and gowns should be removed
carefully to avoid contamina on of the
wearer and the surrounding area.
Fig: 2.4.5 Hand wash
Ÿ Wash your hands o en with soap and water for 20 seconds.
} Wash your hands immediately a er removing gloves and a er contact with a person who is
sick.
Ÿ Follow normal preven ve ac ons while at work and home, including washing hands o en for at
least 20 seconds and avoiding touching eyes, nose, or mouth with unwashed hands. It is especially
important to wash hands:
} A er blowing one’s nose, coughing, or sneezing.
} Before touching one’s face.
} A er using the restroom.
} A er leaving a public place.
} A er handling one’s mask.
} A er changing a diaper.
} Before ea ng or preparing food.
} A er touching animals or pets.
} A er caring for an ill person.
Hand sani zer: If soap and water are not available and
hands are not visibly dirty, an alcohol-based hand sani zer
that contains at least 60% alcohol may be used. However, if
hands are visibly dirty, always wash hands with soap and Fig: 2.4.6 Using hand sani zer
water for at least 20 seconds.

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2.4.5 Stress Management During An Epidemic

Stress during an infec ous disease outbreak can some mes cause the following:
Ÿ Fear and worry about your own health and the health of your loved ones, r financial situa on or job,
or loss of support services you rely on.
Ÿ Changes in sleep or ea ng pa erns.
Ÿ Difficulty sleeping or concentra ng.
Ÿ Worsening of chronic health problems.
Ÿ Worsening of mental health condi ons.
Ÿ Increased use of tobacco, and/or alcohol and other substances.
Healthy ways to handle stress
Ÿ Know what to do if you are sick
Ÿ Know where and how to get treatment and other support services and resources
Ÿ Take care of your emo onal health. This will help you think clearly and react to the urgent needs to
protect yourself and your family.
Ÿ Take breaks from watching, reading, or listening to news stories, including those on social media.
Hearing about the pandemic repeatedly can be upse ng.
Ÿ Take care of your body.
} Take deep breaths, stretch, or meditateexternal icon.
} Try to eat healthy, well-balanced meals.
} Exercise regularly.
} Get plenty of sleep.
} Avoid excessive alcohol and drug use.
Ÿ Make me to unwind. Try to do some other ac vi es you enjoy.
Ÿ Connect with others. Talk with people you trust about your concerns and how you are feeling.
Ÿ Connect with your community - or faith-based organiza ons. While social distancing measures are
in place, consider connec ng online, through social media, or by phone or mail.

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FOCUS ON GETTING WELL ENGAGE YOUR EAT WELL, STAY HEYDRATED

+ NOT SPREADING IT. SUPPORT NETWORK. + MEDITATE

DO ENJOYABLE MAKE SURE YOU’RE STEP BACK FROM THE

RALAXING ACTIVITIES. SLEEPING ENOUGH. NEWS + SOCIAL MEDIA.

Fig: 2.4.7 Tips for stress management

2.4.5 Stress Management During An Epidemic

1. In health and safety context, a hazard is:
a. Anything with the poten al to result in an injury or illness.
b. The likelihood of someone being injured in the workplace.
c. Anything that could result in a physical injury.
d. Anything that could result in a psychological injury.
2. Once you have spo ed a hazard you must:
a. Report it to your boss

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b. Leave it as someone else will fix it eventually

c. Bring your own toolbox to work and fix it yourself
d. None of the above
3. From the following op ons, what is the best way to control hazards in the workplace?
a. Replace the hazard for a less risky op on
b. Eliminate the hazard completely from the workplace
c. Use personal protec ve equipment (PPE)
d. Have rules to help people avoid hur ng themselves
4. The safe way of working is:
a. An effec ve and right way of working b. An ancient way of working
c. A way of handling the work in a hurry d. A way of normal working
5. The best way of avoiding accident is by:
a. Doing work in ancient way
b. Doing work in one’s own way
c. Observing safety rules related to job, machine and workplace
d. Using safety equipment
6. Employers have to provide a safe and healthy place for:
a. Employees only. b. Workers only.
c. Employees and Workers only. d. Employees & Workers
7. You have been given a dust mask to protect against hazardous fumes. What should you do?
a. Do the job but work quickly
b. Do not start work un l you have the correct Respiratory Protec ve Equipment
c. Start work but take a break now and again
D. Wear a second dust mask on top of the first one
8. If you drop your safety helmet from height on to a hard surface, you should:
a. Repair any cracks then carry on wearing it
b. Make sure there are no cracks then carry on wearing it
c. Work without a safety helmet un l you can get a new one
d. Stop work and get a new safety helmet
9. What type of breathing protec on do you use in a space with li le oxygen?
a. A disposable mask
b. Self-contained breathing apparatus.
c. A filter mask with the correct filter cartridge.
d. None of these

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10. The risk of manual task injuries are increased by:

a. The length of me spent handling the load
b. Twis ng sideways, bending and stretching
c. Using trolleys and hoists
d. Wearing a back brace
11. What is a frequent cause of stumbling, slipping or tripping?
a. Failure to wear safety footwear.
b. The lack of barrier tape along a footpath.
c. The presence of cables and pipes lying across a footpath.
d. None of these
12. What should bbe your first ac on, when trea ng an electrical burn?
a. Ensure that the casualty is s ll breathing.
b. Wash the burn with cold water.
c. Check for danger and ensure that contact with the electrical source is broken.
d. Check for level of response.
13. What is a faint?
a. A response to fear.
b. An unexpected collapse.
c. A brief loss of consciousness.
d. A sign of flu.
14. What steps would you take to control bleeding from a nosebleed?
a. Sit casualty down, lean forward and pinch so part of nose.
b. Sit casualty down, lean backward and pinch so part of nose.
c. Lie casualty down and pinch so part of nose.
d. Lie casualty down and pinch top of nose.
15. What is first aid?
a. Comple ng a primary survey
b. The first help given to the vic m of an accident
c. Assessing a vic m’s vital signs
d. Trea ng a vic m for shock
16. The best treatment for all heart a ack vic ms is immediate CPR.
TRUE FALSE

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Answer the Following Ques ons:

17. What are the benefits of organiza on policies and procedure?
_______________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
18. What are the obstacles to effec ve me management?
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

Scan the QR Code to watch the related video

www.youtube.com/watch?v=88PGRvB-Scs www.youtube.com/watch?v=QGHBq5OEsBM
Workplace e que es Effec ve communica on at workplace

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Par cipant Handbook

3. Op mize Resource
U liza on

Unit 3.1 - Resource Op miza on

Unit 3.2 - Waste Management

ASC/N9801
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 Electric Vehicle Service Technician

Key Learning Outcomes

At the end of this unit, the trainee will be able to:
1. List the ways to op mize usage of resources
2. Employ ways for efficient u liza on of material and water
3. Use energy efficient electrical appliances and devices to ensure energy conserva on
4. Discuss various methods of waste management and its disposal
5. List the different categories of waste for the purpose of segrega on
6. Differen ate between recyclable and non-recyclable waste
7. State the importance of using appropriate colour dustbins for different types of waste
8. Demonstrate different disposal techniques depending upon different types of waste

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Unit 3.1 - Resource Op miza on

Unit Objec ves

At the end of this unit, the trainee will be able to:
1. List the ways to op mize usage of resources
2. Employ ways for efficient u liza on of material and water
3. Use energy efficient electrical appliances and devices to ensure energy conserva on

3.1.1 Energy Conserva on

In today’s world, the automo ve industry con nuously explores new opportuni es for energy efficiency
op ons. The company aims to reduce produc on costs and yet maintaining the quality of the product,
customer sa sfac on and safety of the passengers in their automobiles. Energy efficiency is crucial to
reduce the pollutant emissions into the atmosphere and the automakers find it challenging to increase
the output of the products and adhering to energy efficiency prac ces.
Ÿ Energy management programs and systems: As the technology of saving energy on equipment is
becoming more complex and advanced, so do the impact and changes in employees’ a tudes and
behaviours.
} For the employees to adopt the energy management prac ces in their daily work life, they must
undergo energy management training programs and adapt to such changes in their rou ne
tasks.
} Every level of management from top to bo om of the authority levels must work together to
a ain the company objec ves and missions of energy efficiency and become aware and
conscious of their energy consump on.
} Conduc ng regular feedbacks and sugges ons between all employees and employers in the
programs and introducing incen ves such as the reward system may mo vate par cipants at all
levels.
} Although employees take small steps and only saves a small amount of energy by switching off
the electronic devices, etc. but when they con nuously do those small li le steps, in the long
run, the company saves a huge amount of energy consump on costs and shows greater impact
than inves ng in technology development.
Ÿ Efficient HVAC (hea ng, ven la ng and air condi oning) measures: HVAC consumes the largest
amount of electricity in the automo ve assembly plants during opera ons; it’s ven la ng the
system when the fuel operates with high energy for drying and hea ng in pain ng.
} Therefore, a great way to save energy from the HVAC system is by se ng the temperature of the
premises lesser during non-opera ng days such as weekends and public holidays. It can be
evidenced just as simple as turning off the electronic air condi oning controls a er opera ng
hours during these periods.
} Adjus ng the fans by using different shape or size of the sheaves of a fan helps to control the
airflow and fan speed which eventually saves energy in the vehicle plant facility.

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Fig: 3.1.1 HVAC system

} Reducing the usage of air condi oning by plan ng trees that give shades and cool down the
building temperatures especially in hot climate areas is warranted immensely.
The bigger is the area of the facility plant, the higher is the ven la on system usage and energy
used. The proper distribu on of the HVAC system rightly plays an important role that helps save
energy throughout the plant facility.
Ÿ Maintenance and control check: In the long run, the pain ng lines start to func on less efficiently
and the other machinery parts also become more deteriorated. The more care of your car, the
greater it will perform and saves the environment.
Ÿ The following list shall be considered as maintenance checks:
} Install only well- func oned airlocks, windows, entry and exit doors which cause heat losses in
the plant facility.
} Monitor the air exhaust from the ovens so as not to be excessive in the plant facility. Ovens help
to heat up the automobiles so to ensure that the hot air transmission from ovens is not too high.
} Examine the assembly line system that handles coordina on between the material parts and
check any errors to avoid undesirable failure that cause slowdowns the automobile produc on
process.
} Install the direct air condi oning towers rather than overhead tubes in the facility and
maintained the air condi oner regularly.
} Regularly record of performance parameters such as OEE or KPI (Overall Equipment Efficiency or
Key performance indicator) to measure the efficiency of implemented facility management
services.
Ÿ Design environmentally automobile and structure: Electric cars are the latest trend in the
automo ve industry nowadays which relate to energy efficiency. Most car companies manufacture
eco-friendlier electric cars and start to increase the numbers of car charging points whether at
parking areas, shopping malls, gas sta ons or office buildings, etc. Weight or load is also another
factor that determines the cars’ energy usage. If the car is transpor ng heavy weights, it is highly
likely that the car should consume more fuel to travel. Most people leave old or unnecessary items in
their car trunks. Every item increases more weight that will use up more fuels while driving which
eventually incur more costs and destroying the environment as well. Thus, automakers should

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produce automobiles with lightweight materials for the components and parts which help the
drivers to owning lightweight automobiles which save up on fuel usage.
Ÿ Prevent leaks in equipment, compressor and pipes: Leaks can be a major source of wasted energy,
and correc ng them can provide significant immediate savings. Reports indicate that leaks can lead
to a 20 to 30 percent loss of a compressor’s output. They can also diminish the effec veness of your
equipment.
There are various ways to determine leaks in system like undertaking an air leak survey. Ultrasonic
detec on equipment is available for finding smaller leaks as well. Common causes for leaks include
missing seals or welds, loose tubes and hoses and worn materials. Leaks can cause delayed the
produc on down me, increase facility maintenance and shorten its life expectancy. Depending on
the cause, rec fying leaks may be as simple as ghtening up fi ngs or replacing minor parts.
Repairing and fixing the leaking pipes or equipment reduced the electricity bills. To detect the
leakage, iden fy the high hissing sound from the air leakage. Another way is to use soapy water to
detect large leaks. Reduce the pressure to improve the energy efficiency of your compressed air
systems. Turn off the compressor when not in use especially a er opera ng hours, night me or
during tea breaks to save electricity.
Ÿ Upgrading equipment: Keeping equipment in good working condi on is vital to becoming more
energy efficient. Retro-commissioning systema cally looks for equipment in facility opera ng below
op mal standards. Retro-fi ng involves replacing outdated or inefficient equipment.
Ÿ Install energy-efficient ligh ng: Manufacturing facili es need to be well-lit, so it’s cri cal that energy
efficient ligh ng is properly installed. Industrial compact fluorescent light bulbs (CFLs) or light-
emi ng diodes (LEDs) can help businesses use less energy.
Another considera on is to turn off or remove lights in non-essen al areas. For example, many
manufacturers have vending machines in their facili es. Placing vending machines in well-lit areas,
but removing their individual light bulbs can help you reduce some of your electrical usage.
Ÿ Power down the equipment: Virtually every piece of technology in facility runs on electricity.
Shu ng down equipment at the end of the day seems to be a no brainer, but it can be overlooked.
When your employees are not in their offices, whether it is overnight or for an extended vaca on,
remind them to shut down their computers and other equipment, or place them into sleep mode.
And if you have networked computers, your administrator might be able to adjust power se ngs for
more efficient usage.
Ÿ Improve process hea ng: Process hea ng is required to make most consumer and industrial goods,
and it can be responsible for more than one-third of a facility’s energy usage. Manufacturers can save
energy within this area by installing waste heat recovery systems, leveraging alterna ve fuels with
higher combus on efficiency, installing automa c blowdown control systems, affirming proper
furnace installa on and controlling exhaust gases.

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3.1.2 Water Conserva on

We can save water in industries by crea ng awareness in employees, measuring water consump on,
op mum use of water, recycling of waste water, installing water saving equipment, rou ne checks for
pipes etc.
Only 3% of water on Earth is pure and can be used for daily rou ne. Out of 3% water 5-10% (as of 1999)
water is consumed for industrial purpose. As world popula on will grow water consump on also will
grow. By 2030 it can go upto 15-20%, so there is need to spread awareness on ways to save water in
industries by reducing its consump on
Ways to conserve water in industry.
Ÿ Educate employees: Build understanding in employees why
water is important and let them innovate ways to water
conserva on.
Ÿ What is current water consump on: Know current water
consump on to set target for next cycle. It can be month or
quarter or year. It will help to iden fy peaks mes, loca ons
which are using more water, leaks and equipment.
Fig: 3.1.2 No ng water
Ÿ Rou ne Checks: Installa on on monitoring, water pressure Consump on reading
meter and water flow meter will help to iden fy leakage in pipes,
joints or valves.
Ÿ Minimal use in Cleaning: To avoid high water consump on, shi to
electric brooms, vacuum cleaner or other cleaning devices (like
squeegees etc.) in ini al process. Wash equipment as and when
required than regularly. Reduce the uses of water sprinkler.
Ÿ Retrofit exis ng equipment and fixtures: Se ng appliance
parameters to meet the minimum water requirement for usage;
installing automa c shut-off nozzles to hoses; switching to high
pressure, low-volume hose nozzles; and installing water efficient sink
faucets, shower heads, and toilets are several ways to retrofit exis ng
equipment to save water.
Fig: 3.1.3 Water wastage
Ÿ Install water saving equipment: There are plenty of water
conserva on equipment are available. Consider using
them. Such as toilet systems, tap aerators, also replace
tap from high volume to high pressure and low volume.
Ÿ Reduce the amount of blowdown water from cooling
towers by carefully maximizing cycles of concentra on:
Cooling towers are o en the greatest consumers in
industrial opera ons, providing considerable opportunity
for advancement. Each cooling tower cycle, wastewater
high in dissolved solids leaves the tower and is replaced by
fresh water. If monitored carefully, industries can
significantly reduce their fresh water usage.
Ÿ Water recycling: It is wrong assump on that all processes Fig: 3.1.4 Water saving equipment
require pure drinking water in business. We can reuse water
(Non-Potable) in plant wherever possible. Installa on of cooling tower to recycle water with efficient
refrigera on loop can save upto 25% of total water consump on.

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Ÿ Ways to reuse water: Save water in Industries by Reuse Uhle-box seal water. Centrifugal pump seal
water, vacuum pump seal water and condenser water for steam makeup can be reuse to save water.
Ÿ Reverse Osmosis: Industries can consider reverse osmosis unit to treat water. Although energy
consumed by this plant is much higher but it worth it.

Fig: 3.1.5 Water recycling process

Ÿ Effluent and sewage water treatment plant: Industries can use ETP (effluent treatment plant) and
STP (sewage treatment plant) to treat waste water, so that it can be recycled for flush in toilet and
floor cleaning.
Ÿ Replace outdated equipment with energy-efficient alterna ves: Water usage is also cut by
inves ng in equipment with water-saving technology or “dry” equipment that doesn’t require water.
One example is using air-cooled equipment (such as an air-cooled compressor), in place of water-
cooled equipment whenever possible.
Ÿ Reuse non-potable water for other opera ons. Water le over from one sector of an opera on can
be reused for another purpose. For example, water used for cleaning can be filtered and reused for
landscaping, or for cooling equipment. Another example is taking otherwise wasted condensate
water from cooling towers and reusing it as “make up” water, or water that is used to replace water
lost by evapora on.

Notes
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Unit 3.2 - Waste Management

Unit Objec ves

At the end of this unit, the trainee will be able to:
1. Discuss various methods of waste management and its disposal
2. List the different categories of waste for the purpose of segrega on
3. Differen ate between recyclable and non-recyclable waste
4. State the importance of using appropriate colour dustbins for different types of waste
5. Demonstrate different disposal techniques depending upon different types of waste

3.2.1 Waste Management

Waste management is gathering, transport, recycling, processing and disposal of waste materials.
Waste management is carried by recovering resources from waste materials.
It involves waste substances (i.e. gaseous, solid, liquid or radioac ve), expert personnel and different
methods of management.
Classifica on of wastes typically as follows:
Ÿ Garbage i.e. decomposable waste
Ÿ Rubbish: paper, wood, cloth i.e. combus ble in nature and metal, glass, ceramics i.e.
noncombus ble in nature and non-decomposable wastes
Ÿ Ashes
Ÿ Sewage-treatment solids: material reserved on se led solids, biomass sludge and sewagetreatment
screens
Ÿ Industrial wastes: like chemicals, paints etc.
Ÿ Mining wastes: slag heaps and coal refuse piles

3.2.2 Types of Waste in Industry

Generally five types of waste are iden fied in industry, these
are:
1. Liquid Waste: Liquid waste is commonly found both in
households as well as in industries. This waste includes dirty
water, organic liquids, wash water, waste detergents and
even rainwater.
2. Solid Rubbish: Solid rubbish can include a variety of items
found in commercial and industrial loca ons. Solid rubbish is
commonly broken down into the following types:
Fig:. 3.2.1 Liquid Waste

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Ÿ Plas c waste - This consists of bags, containers, jars,

bo les and many other products that can be found.
Plas c is not biodegradable, but many types of plas c can
be recycled. Plas c should not be mix in with regular
waste, it should be sorted and placed in recycling bin.
Ÿ Paper/card waste - This includes packaging materials,
newspapers, cardboards and other products. Paper can
easily be recycled and reused so make sure to place them
in recycling bin. Fig:. 3.2.2 Solid Rubbish
Ÿ Tins and metals - This can be found in various forms throughout
in industry. Most metals can be recycled. Consider taking these items to a scrap yard to dispose
of this waste type properly.
Ÿ Ceramics and glass - These items can easily be
recycled. Look for special glass recycling bins
and bo le banks to dispose them correctly.
3. Organic Waste: Organic waste is another common
type of waste. All food waste, garden waste,
manure and ro en meat are classified as organic
waste. Over me, organic waste is turned into
manure by microorganisms. However, this does not
mean that you can cdispose them anywhere.
Fig:. 3.2.3 Organic Waste
Organic waste in landfills causes the produc on of
methane, so it must never be simply discarded with
general waste.
4. Recyclable Rubbish: Recyclable rubbish includes all
waste items that can be converted into products
that can be used again. Solid items such as paper,
metals, furniture and organic waste can all be
recycled.
5. Hazardous Waste: Hazardous waste includes all
types of rubbish that are flammable, toxic, corrosive
and reac ve
Fig:. 3.2.4 Hazardous Waste

Fig:. 3.2.5 Recyclable Waste

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3.2.3 Elements of Waste Management Strategy

Good waste management prac ces involve much more than that disposing of waste legally and
properly. Strategy for the management of industrial waste can include the subsequent elements:
Ÿ Current waste management procedures and primary audit of wastes produced.
Ÿ Risk assessment to find that stowage and handling procedures does not possess any health or
environmental risk.
Ÿ Iden fica on of op ons for reuse, waste reduc on, recovery assessment and recycling of waste.
Ÿ Iden fica on of best prac cable environment! There should be an op on for dumping of waste and
residues.
Ÿ Selec on of the contractor offering the best service and audit of poten al waste management
contractors.

3.2.4 Methods of Waste Management

1. Segrega on
Why waste separa on using container unit is so necessary because plas cs, building materials, glass
and waste from the site work could take a really long me period to decompose. This is the reason,
thus, it is required to maintain green prac ces so waste management should be done with proper
segrega on. Thus we make sure to support you in removing hazardous waste from compostable
non-hazardous solid waste, organic waste, recyclable materials and other regulated material.

Fig: 3.2.6 Waste segrega on

2. Compos ng
This waste management process turns waste into organic compounds
that you can use to feed plants. In terms of the environment advantages
this is actually beneficial technique. Making use of this method, it’s easy
to turn unsafe organic products into safe compost.
3. Landfill
One of the most popularly used methods of waste disposal. This process
buries the waste in the land, but there is more to it. When it comes to
proper landfill management, it is important to sort out all the waste first Fig: 3.2.7 Waste comps ng

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and send only the waste that you cannot recycle or compost. There
is also a method that eliminates the odour and dangers of rubbish
before placing them on the ground

Fig: 3.2.8 Waste landfillin

4. Recycling
Products like PVC, LDEP, PP and PS are recyclable though they are
not collected for recycling. The material, which is composed of a
single type, is recyclables and is much easy to work with. However,
complex products are difficult to treat and so are complex for
recycling.

Fig: 3.2.9 Waste recycling

Notes

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Exercise
1. Tripping over objects can be reduced by ……………………………………………………….
2. Which is not the element of effec ve housekeeping
a. Waste disposal b. Cleaning
c. Machining d. Spill control
3. Spilled oil can be the cause of an accident. True or False?
4. The most serious environmental effect posed by hazardous wastes is:
a. air pollu on. b. contamina on of groundwater.
c. increased use of land for landfills. d. destruc on of habitat.
5. Which of the following is not a primary contributor to the greenhouse effect?
a. carbon dioxide b. carbon monoxide
c. chlorofluorocarbons d. methane gas
6. In health and safety context, a hazard is:
a. Anything that could result in a psychological injury.
b. Anything with the poten al to result in an injury or illness.
c. The likelihood of someone being injured in the workplace.
d. Anything that could result in a physical injury.

Scan the QR Code to watch the related video

www.youtube.com/watch?v=42UHIRVwxec
Waste management and its disposal

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4. Perform rou ne
service and repair
of an Electric
Vehicle
Unit 4.1 - Prerequisites for Service and Repair of Electric
Vehicles
Unit4.2 - Prepare to Carry out Rou ne Service or Minor
Repair
Unit4.3 - Perform Rou ne Service or Minor Repair

ASC/N1449
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Key Learning Objec ves

At the end of this module, the trainee will be able to:
1. Iden fy tools and equipment required for servicing and repairing
2. Demonstrate preparatory ac vi es for diagnosing faults and repairing of an EV
3. Demonstrate how to use different techniques for diagnosing faults and repairing the an EV

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Unit 4.1 - Prerequisites for Service and Repair of Electric

Vehicles

Unit Objec ve
At the end of the unit, the trainee will be able to:
1. Discuss the safety precau ons need to follow during servicing and repairing of an EV
2. Describe five safety rules for electrical work on HV systems before star ng the work
3. Explain the health and safety measures and regula ons w.r.t. equipment and components during
fault diagnosis
4. Describe organiza onal/professional code of ethics and standards of prac ce
5. Explain legal regula ons that need to be taken into account for handling electric vehicles
6. List the types of tools and equipment used in different processes of an EV maintenance
7. Recall fundamental terms, laws and principles of electricity used in EV
8. Describe various symbols, units and terms used in wiring diagrams associated with
electrical/electric systems/components of an EV
9. Describe various electrical and electronic signals such as electrical inputs, outputs, voltage, pulse-
width modula on, digital signal (including infra-red and fiber op cs) etc.
10. List various components /aggregates and the manufacturer's specifica ons of an EV
11. Discuss basic technology used, func oning and interconnec ons of various systems and
components of an EV

4.1.1 An Introduc on to Electric Vehicles

Electric Vehicles (EVs) are vehicles that are powered par ally or fully by a ba ery. The journey of EVs
began in the 1800s and evolved since then and gained popularity. The advent of gasoline vehicles and
their entry into the market saw a decline in the popularity of electric vehicles. In the last few decades,
due to the increased awareness of climate change, environmental issues, air pollu on, focus on
renewable energy, and technological advances, there has been a revival of Evs.

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Ányos Jedlik invented an electric motor in Professor Sibrandus Stra ngh of

1828 and made a small model car University of Groningen, Netherlands
powered by the electric motor he built this small electric car between1832
created. and 1839.

Andreas Flocken created a 4-wheeled Anderson Electric Car Company produced

electric car between 1845-1913. the Detroit Electric in early 1900s and
built 13,000 electric cars between the
years 1907-1939.

Fig. 4.1.1 Evolu on of Electric Vehicles

Pictures Source: h ps://www.upsba erycenter.com/blog/first-model-electric-car-1828/

h ps://www.rug.nl/museum/collec ons/collec on-stories/09-stra ngh.jpg
h ps://upload.wikimedia.org/wikipedia/commons/thumb/8/8c/1888_Flocken_Ele
ktrowagen.jpg/800px-1888_Flocken_Elektrowagen.jpg
h ps://upload.wikimedia.org/wikipedia/commons/f/f2/1911_Detroit_Electric.jpg

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Electric Vehicle Market

In India, the two-wheelers segment dominates the electric vehicle, market. In India, the electric vehicle
market is expected to register a CAGR (Compound Annual Growth Rate) of 47.09% during the forecast
period of 2022-2027. By 2030, NITI Aayog is planning to have a sales penetra on of 80 percent in two
and three-wheelers, 70 percent in commercial cars, and 40 percent in buses. Between 2018-21, India
registered close to five lakh EVs.

Fig. 4.1.2 State Wise EV Sales Trend in 2021

Source: EV Reporter
h ps://www.ibef.org/uploads/blog/1651750845_941c5d39193335049d69.jpg

Notes

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Classifica on of EVs
EVs can be classified into a category based on the type of vehicle and the type of propulsion. Based on
the vehicle type, they are classified as electric two-wheelers, electric three-wheelers, electric four-
wheelers, and electric commercial and heavy vehicles.

Electric two-wheelers: Electric bikes, scooters, mopeds and scooters

for kids.

Electric three-wheelers: Electric rickshaw, passenger auto and cargo

auto.

Electric four-wheelers : Electric cars

Electric commercial and heavy vehicles consist of Electric buses, lorries

and trucks.

Fig. 4.1.3 Classifica on of EVs Based on Type of Vehicle

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Based on propulsion type, they are classified as Ba ery Electric Vehicle (BEV), Plug-in Hybrid Electric
Vehicle (PHEV), Hybrid Electric Vehicle (HEV), and (FCEV).

BEVs are run en rely on ba ery-powered HEVs have an engine and electric motor,
electric drive train. the engine gets energy from fuel and the
motor gets electricity from ba eries. There
is no op on for charging the ba eries
externally

PHEVs have an engine and a motor, the FCEVs have hydrogen fuel cells. The
engine gets power from fuel and the motor chemical energy of the hydrogen fuel is
gets powered by a ba ery which can be converted directly into electric energy,
charged externally. which in turn is used to charge the
ba eries and propel the vehicle

Fig. 4.1.4 Classification of EVs Based on Type of Propulsion

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4.1.2 Safety Prac ces in Service and Repair of Electric Vehicles

Electric vehicles comprise high-voltage components and other aggregates that require safe handling to
prevent injuries, death, or, damage to the equipment and the workplace. There are risks involved while
working with electrical systems, and electricity, hence it is important to make note of all the safety
measures outlined by the manufacturers.
EV motors and ba eries have high electrical and magne c poten al that can cause injuries and even
death if proper precau ons are not taken. High voltage wires are always orange in colour. Electrical
work should be started only a er taking all precau onary measures against short-circuits, electric
shock, and arcs. No work should be performed on live parts of electrical systems and equipment. All
these systems have to be placed in a non-live state before and during the work. A list of poten al hazards
and risks has to be made, and analysed and relevant precau onary steps to prevent them have to be
taken.
Some of the common risks in EV workshops are:

Risks associated with ba ery replacement

Risk of release of harmful liquids and gases from damaged ba eries

Risks associated with AC and DC shocks

Presence of HV components causing fatal electric shock

Poten al risk of explosion and fire due to storage of electrical energy

Presence of components that may retain HV even when the vehicle is switched off

Moving vehicles and electric motors that can move unexpectedly due to magne c forces
inside the motors

Risk to peolpe with medical implants like pacemakers

Fig 4.1.5 Common Risks in EV Workshop

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Electrical work
Electrical work comprises tasks involving electrical systems or within their hazard areas, such as trailing
and measurement, repair replacement of components, modifica on, extension, erec on, and tes ng.
High voltage
In the automo ve sector, par cularly in electric, hybrid, and fuel cell vehicles, high voltage comprises
voltages: 60 V and ≤ 1500 V DC and 30 V and ≤ 1000 V AC.
Electrical hazards
Electrical hazards exist during work on HV systems when the voltage between the live components is
greater than 25 V AC or 60 V DC and the short circuit current where work is being performed exceeds the
value of 3 mA AC or 12 mA DC or the energy exceeds 350 mj.
Electric shocks
Protec on against electric shocks must be given as per statutory regula on, codes of prac ce, and
na onal and company standards. The amount of harm caused by an electric shock depends on the
magnitude and dura on of the current. A low current for a long dura on can also lead to a major injury
or death.
Live work on the HV system
Live work on HV systems is any work on the HV system during which an employee’s body or items (tools,
devices, equipment, or apparatus) come into contact with live parts or work during which the non-live
state is not assured.
A vehicle with an intrinsically safe HV system is one on which technical measures on the vehicle assure
full protec on against electric shock and arcing on the HV system.
Protec on Device
The first-line protec on against high voltages includes direct methods such as:
• enclosure (keeping things covered)
• insula on (always orange-coloured)
• loca on (posi ons to prevent accidental tampering).
The devices available to protect against excess current flow are fuses, miniature circuit breakers (MCBs),
residual current devices (RCDs), and residual current breaker with over currents (RCBOs).

Fuse
• A fuse consists of a thin metal strip or wire which melts when excess current flows through it
and breaks the circuit. Excess current can be caused by overloading, short-circuit, device
failure, mismatched loads, etc.

Miniature Circuit Breaker (MCB)

• An MCB consists of a bimetallic strip which deflects due to the heat caused by excess current
and releases a latch, thereby breaking the circuit. An MCB is more sensi ve than a fuse. They
can be reset by switching them back on.

Con nued...

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Residual Current Device (RCD)

• An RCD provides personal protec on and prevents fatal electric shock if a live connec on is
touched. It can detect electricity flowing through a human body or any other unintended path
and break the circuit immediately, which a fuse or MCB cannot do.

Residual Current Breaker with Over Current (RCBO)

• An RCBO works in the same way as an RCD. Along with protec on of life it also protects an
overload on a circuit. It consists of two circuits, one to detect the overload and the other to
detect the imbalance.

Fig 4.1.6 Protec on Devices

Electrosta c Discharge (ESD) Protec on Methods and Devices:

ESD is the sudden flow of electricity between two electrically charged objects caused by any contact like
an electrical short or dielectric breakdown. All electric components should be placed on an an -sta c
surface like an an sta c discharge mat. It is also advisable to wear an an sta c grounding strap
connected to a metal surface.
Personal Protec ve Equipment
While dealing with high voltage components, safety against Electrosta c Discharge (ESD), High Voltage
(HV) and Ba ery Charging Equipment have to be taken. Along with general PPE, the technician should
use:

Hard hats, while working under the carriage

Safety glasses with shields

Footwear with safety/steel-toed boots, rated dielectric footwear

Insula ng gloves

Insulated tools

Electrical/Insula on blankets

Fig. 4.1.7 PPE to be used for HV Work

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Specifica ons of Electrical Safety Gloves

Gloves should be free from any defects like holes, cuts, tears, etc. They have to be checked for air leakage
and swelling. Defec ve gloves should be discarded and not be used while working. There are various
types of electrical safety gloves available and they are classified based on the level of voltage protec on
they can give as shown below:

Class 00- It is rated at a maximum use voltage of 750V DC/500V AC

Class 0- It is rated at a maximum use voltage of 1,500V DC/1,000V AC

Class 1- It is rated at a maximum use voltage of 11,250V DC/7,500V AC

Fig 4.1.8 Classifica on of Electrical Safety Gloves

Safety Measures to be Taken for Various Work Categories

The various categories of work and the safety measures to be taken are as follows:

Low risk ac vi es

• People who are moving around EVs and also people who are opera ng the EVs inside the
premises like valet and sales execu ves should be cau ous to prevent any kind of accidents.
• Remote opra ng keys should be kept away from the vehicle to prevent the vehicle from
accidentally moving.
• Ac vi es like pressure washing can damage HV cables and parts, therefore, precau onary
measures have to be taken.

Emergency services

• EVs have to be inspected to see if there are any damaged HV cables/ components, ba eries,
loss of coolant, damage to vehicle, etc.
• In such situa ons, the HV ba ery system has to be isolated using isola on device, remote
opera on key has to be removed, the low-voltage ba ery has to be disconnected and towing of
vehicles has to be avoided.

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Maintenance and repair of non-HV components

• Always refer to OEM instruc on and guidelines.

• Keep remote opera ons keys away from vehicle to prevent any accidental movement of vehicle
or opera on of electrical systems, if keys are required, then the technician should ensure that
the vehicle is secured and in safe condi on before the key is retrieved.
• Visual inspec on of HV cables and other electrical components should be checked before
star ng any work.
• If the vehicle needs to be energized, isolate or disconnect the HV ba ery as per OEM
guideleines and then start work.
• Work on live electrical components should be carried out only if there is no other way to work
on it. Wearing of PPE and other protec ve measures have to be taken in such instances.

Working on HV electrical systems

• Always refer to OEM instruc on and guidelines.

• Keep remote opera ons keys away from vehicle to prevent any accidental movement of vehicle
or opera on of electrical systems, if keys are required, then the technician should ensure that
the vehicle is secured and in safe condi on before the key is retrieved.
• Visual inspec on of HV cables and other electrical components should be checked before
star ng any work.
• HV systems, cables and componets should be isolated and Safeguard against reconnec on.
• before working on it.
• Ba eries and other components may have large amounts of energy even a er isola on,
therefore insulated tools and tes ng equipment have to be used.
• Electronic components can store large amounts of electricity even a er isola on, this has to be
discharged by following the guidelines given by OEM.
• Before carrying out pain ng and other works, where the temperaures may exceed the
tolerance limit of ba ery packs, measures like removing the ba eries and providing insula on
to ba eries have to be taken.
• Work on live electrical components should be carried out only if there is no other way to work
on it. Wearing of PPE and other protec ve measures have to be taken in such instances.
• Warning signs should be palced around the work area to make people aware of the dangers.

Fig 4.1.9 Safety Measures to be Taken for Various Work Categories

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Safety Measures to be Taken While Working on Evs

It is essen al to take appropriate safety precau ons before, during, and a er maintenance, servicing,
and repair work. The following steps should be taken while working on Evs:

Before work begins

• Isolate by switching off the igni on, removing service plug/maintenance connector or

switching off the main ba ery switch, removing fuses and low-voltage ba ery.
• Protect against reconnec on by removing the igni on key and prevent unauthorized access to
it, storing the service plug/maintenance connector against unauthorised access to it, protect
the main ba ery switch against reconnec on. Follow OEM instruc ons.
• Check for non-live state as per OEM instruc ons and also using suitable test apparatus like
voltage testers.
• Wait for a 5-10 minutes minutes to allow storage capacitors to discharge before taking up the
work.
• Ensure that the junc on board terminal voltage is close to Zero Volts.
• Place guards and warning signage as required around the work area.

During work

• Preven on of short-circuits between components and shor ng to ground are prevented even
a er disconnec ng.
• Ba ery can be live even a er disconnec on, therfore, it is advisable to cover adjacent live
parts.
• Insula ng gloves and boots have to be worn always while working on Evs.
• Insulated tools have to be used while perfoming maintenance work on high-voltage systems.

Interrup on to work

• Ensure that the vehicle remains de-energized and isolated when work procedures get
interuppted while HV components are exposed or disassembled.
• Ensure that the igni on is turned off and the key is removed.
• Ensure that the ba ery module is switched off.
• Prevent unauthorized people from entering the area and touching components.
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 Electric Vehicle Service Technician

A er comple on of work

• Ensure that all terminlas are ghtened to the specific torque before switching on the ba ery
module switch or re-energizing.
• Ensure that no high-voltage terminals and wires are damaged or shorted to the body.
• Check the insula on resistance between the high-voltage terminal of the part that was
diassembeld and the vehicle's body.
• All tools, equipment and other materials should be cleared from the work area.
• All the guards and warning signage have to be removed.

Fig 4.1.10 Safety Measures to be Taken While Working on EVs

Safety Measures to be Taken While Working on HV Systems

The five safety measures to be taken while working on HV systems are:
• Isolate
• Safeguard
• Verify non-live state
• Earth or short circuit
• Shroud or safeguard adjacent live parts
Health and Safety Measures to be Taken Concerning Equipment and Components
It is important to follow health and safety measures at the workplace to protect men, materials, and
machines. The risk of injuries to workers and damage to equipment is very while diagnosing faults in EVs.
Every organisa on has to be compliant with health and safety guidelines provided by the State and legal
authori es. All the technicians have to be trained to understand the risk involved in dealing with faulty
components and equipment and the safety precau ons that need to be taken to prevent incidents.
Some of the prac ces to be followed are:

Know the risks associated with faulty components and equipment.

Faulty components can damage to the technician as well as to other components inside and
outside the vehicle, therefore, know the precau ons to be taken.

Wear PPE as required.

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Use only OEM approved spare parts and procedures for fault diagnosis and replacement of parts.

Use guards and protec ve devices to reduce and maintain safety.

Only trained persons should be allowed to perform the fault diagnosis and other risky
opera ons under proper supervision.

Use technology to the maximum extent to detect faults.

Report injuries, incidents and accidents to the designated people.

Place appropriate singage to warn others and prevent accidents.

Fig. 4.1.11 Health and Safety Prac ces at the Workplace

4.1.3 Professional Code of Ethics and SOP

The professional code of ethics outlines the principles that govern the organisa on’s behaviour and
decisions. They provide an outline of how the workers should behave, and give guidance related to
handling issues like safety, harassment, abuse, and conflict of interests. This helps the workers to
understand what kind of behaviour and decisions are acceptable in the organisa on. Some of the
aspects that can be included in the professional code of conduct and ethics are:

Legal compliance

Conflicts of interest

An -corrup on

Protec ng company assets

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Punctuality and a endance

Harassment (including sexual harassment)

Dress/ Uniform code

Do not use tobacco, alcohol, smoking, etc.

Fig. 4.1.12 Professional Code of Conduct and Ethics

Standard Opera ng Procedures (SOPs)

These are the documented processes that an organisa on follows to ensure the work or service quality
are maintained and delivered consistently. SOPs help in preven ng risks, reducing errors, minimizing
rework, and achieving greater efficiency. It also helps to show compliance with the regulatory bodies
and organiza onal regula ons. SOPs vary from sector to sector, industry to industry, and department to
department.
SOPs for EV Workshop
The SOPs for the EV workshop can be discussed under the following categories:
• Safety precau ons
• Procedures and processes
• Recording and repor ng
SOPs for Safety Precau ons

Use of PPE by workers

Safe usage, maintenance and storing of tools, equipment and machines

Safety precau ons to be taken while handling HV components

Risk iden fica on, analysis and assessment

Provision for first-aid and first box

Fire safety instruc ons including fire alarms, ex nguishers, evacua on plan,
safe assembly points etc.

Maintaining a safe and clean workplace

Fig. 4.1.13 SOPs for Safety Procedures

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SOPs for Carrying Rou ne Work on EVs

Procedures to use tools and equipment for a specific job

Procedures for preparing the vehicle for servicing/maintenance/repair

Procedures for carrying out specific jobs as per OEM

Procedures for pre and post servicing inspec on

Procedures for iden fica on of faults

Procedures for replacing faulty components, etc.

Fig. 4.1.14 SOPs for Carrying Rou ne Work on EVs

SOPs for Recording and Repor ng

Defec ve and faulty tools, equipment and machines.

Hazards and risks in workplace

Accidents and incidents in workplace, etc.

Fig. 4.1.15 SOPs for Recording and Repor ng

Documenta on
All the work carried out has to be documented for future reference. The main objec ves of
documenta on are:

To record details of vehicle and date and me of servicing.

To record details of the inspec on carried out.

To record details of faults and problems found.

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 Electric Vehicle Service Technician

To report problems that cannot be addressed by self to designated person.

To record correc ve ac on taken.

To record details of the person who has carried out the work.

Fig. 4.1.16 Importance of Documenta on

4.1.4 Tools and Equipment

The various tools and equipment used in the maintenance, servicing, and repairing of EVs can be broadly
classified as hand tools, tes ng equipment, and workshop equipment.
SOP for Using Tools:

Use a tool for its intended purpose

Use the correct size of tool

A er use, clean the tools and keep it back in its kit

Do not use damaged or defec ve tools

Inspect tools regularly for damage

Report and replace damaged tools

Record details of damaged tools in tool log book

Ensure that the tools are calibrated as per manufacturer's guidelines

Fig. 4.1.17 SOP for Using Tools

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Hand Tools
Hand tools are tools like spanners, hammers, screwdrivers, etc. which are used for basic opera ons like
loosening and ghtening nuts and bolts/ screws, etc. Most of the hand tools are part of the normal tool
kit. Special tools are those tools that are generally not part of the regular toolset and used for a specific
job.

Hand tools Image

Spanner is used to provide grip while applying

torque to objects like nuts and bolts. The most
common types of spanners are:
• Adjustable spanners are used for holding one
end of a nut and bolt.
• Open-ended spanners are used where access
to nuts and bolts is limited.
• Ring spanners are used for holding hexagon
bolts and nuts.

Wrenches are used for holding, ghtening,

loosening, and turning fi ngs, nuts, and bolts.
The most common types of wrenches are:
• Socket wrench contains a ratchet to simplify
the opera on.
• Torque wrench is used for correct ghtening
of fixings.

Screwdrivers are used to remove and install

screws. They can be manually operated or power
operated. The different types of screwdrivers are:
• Flat- p screwdrivers are used to turn slo ed
screws.
• Philips-head screwdrivers are used to ghten
or loosen screws that are cross-headed.
• Torx screwdrivers are used to fasten or loosen
screws that have star-shaped depression.

Pliers and Wire cu ers are used to grip small

objects, hold wires, bend wires and loops and
a ach wires. They can also be used to cut wires
with minimal damage to the insula on or internal
conductors.

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Hand tools Image

Crimpers are used to connect wires and wires to

other connectors.

Table 4.1.1 Hand Tools

Tes ng Equipment
Tes ng equipment or measuring equipment are used to measure and compare the measured result
with data. They are different types of tes ng equipment like measuring equipment, hand instruments,
electrical meters, etc. Voltmeters used for EV work should be rated to a minimum of 1000V.

Tes ng/Measuring equipment Image

Vernier calipers are used to measure the inner

and outer dimensions of objects.

Micrometers are used to measure the thickness,

diameter, and length of solid objects.

Spring balance is a type of weighing scale. It

consists of a spring that is fixed on one end and a
hook on the other end to a ach the object that
needs to be weighed.

h ps://upload.wikimedia.org/wikipedia/comm
ons/4/4f/Weeghaak.JPG

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Tes ng/Measuring equipment Image

A tester is a screwdriver-like tool used to

determine the presence of electricity in a piece of
equipment under test. The p of the tester is
touched to the conductor being tested (for
instance, it can be used on a wire in a switch, or
inserted into a hole of an electric socket). A neon
lamp takes minimal current to light and thus can
use the user's body capacitance to earth ground
to complete the circuit.

Mul meters are also known as Volt/Ohm meters

or VOM. they are used to measure voltage,
resistance, and current. The different types of
mul meters available are Megger, Snap-on scope
meter, Fluke 78 Automo ve, Uni-T amp clamp,
etc.

An Oscilloscope is a voltmeter, it shows the

voltage levels by a trace or mark on the monitor
allowing us to see the way voltages change.

Table 4.1.2 Tes ng Equipment

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Instruc ons for Using Tes ng Equipment

Always follow manufacturer’s instruc ons

Handle them with care

Calibrate regularly to maintain accuracy

Do not use damaged or defec ve tes ng equipment

A er use, clean the tes ng equipment and keep it back in its kit

Fig. 4.1.18 Instruc ons for using Tes ng Equipment

Workshop Equipment
Workshop equipment is used mainly for raising vehicles, to li ba ery packs, li ,and suppor ng the
vehicle while changing tyres, etc. Some of the examples are cranes, ramps, hoists, jacks and axles, parts
washers, steam cleaners, etc.

Workshop equipment Image

Electric drills or power drills are used to make a

hole in a variety of materials and also to drive
screws through different materials.

An Air gun is used to remove wheel nuts or bolts

using a high-pressure air supply.

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Workshop equipment Image

Cranes are used to li and lower or move material

and objects horizontally with help of hoist chains
and cables.

Source: www.eurocarparts.com

Ramps and hoists are used to li vehicles so that

repair and maintenance work on the
undercarriage of vehicles can be carried out.

Source: www.eurocarparts.com

Jack and axle stand is used to support the weight

of vehicles and hold it in place while replacing
tyres and other parts under the vehicle.

Table 4.1.3 Workshop Equipment

High-Voltage Tools
High-voltage tools are insulated tools used while working on HV electrical components and devices, for
example, insulated wrench, insulated screwdrivers, insulated pliers, etc. They are typically designed to
protect up to 1000V. The insulated tools have a two-step color-coded system, an orange outer insula on
material, and a bright yellow inner material. If the outer area is worn-out and the yellow part is visible,
then the tool is no longer safe to use.
On-board diagnos cs (OBD)
OBD is a computer-based system inside a vehicle used to track and regulate its performance and also
alert the user. A technician can plug into the vehicle and get the status of the various vehicle sub-
systems. They are used to carry out tests on vehicle systems either with the help of manuals or guided by
the computer. The modern OBD systems provide real- me data along with standardized series of
diagnos c trouble codes, that allow the technician to iden fy faults and remedy faults in the vehicle.

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4.1.5 Electrical and Electronic Principles

Electrical devices convert electrical energy to other forms of energy like heat, light, etc. These types of
devices use electrical energy to perform work. It uses the metal of conduc on. Electrical devices
generally work on alternate current (AC). Home appliances like toasters, microwaves, heaters, mixers,
and blenders, etc. are examples of electrical devices.
Electronic devices control the flow of electrons to perform a par cular task. It uses semiconductor
materials like silicon, germanium, etc. These devices generally work on Direct Current (DC). Laptops,
computers, mobile phones, etc. are examples of electronic devices.
Electron and Conven onal Current Flow
All ma er is made up of ny par cles called an atom. An atom consists of a central nucleus made up of
protons and neutrons and around the nucleus, the electrons orbi ng the nucleus. Neutron has no
charges; hence do not have polarity. The protons are posi vely charged and therefore the nucleus is
posi vely charged. The electrons are nega vely charged. When the atoms are in a balanced state, the
protons and electrons are in equal numbers. In some materials, the atoms have electrons that can easily
get detached from the parent atom and join an adjacent atom. Such electrons are called free electrons.
An electric current is the flow of electrons around a circuit.
In Conven onal current flow, electrons flow from the posi ve terminal to the nega ve terminal. In
Electron current flow, electrons flow from the nega ve terminal to the posi ve terminal. Electron
flow is the opposite of conven onal current flow. The image below shows the current moving from
the nega ve terminal of the ba ery to the ba ery's posi ve terminal.

Conve onal Flow Nota on Electron Flow Nota on

Electrons flow from the posi ve Electrons flow from nega ve

(surplus) side of the ba ery to the (surplus) side of the ba ery to the
nega ve (deficiency) side. posi ve (deficiency) side.

Fig. 4.1.19 Conventional and Electron Flow Notations

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Effects of Current Flow

There are three different effects of current flow in a circuit. They are hea ng, magne c and chemical
effects.

Effects of Current Flow

Hea ng Effect Magne c Effect Chemical Effect

The conductor heats up when When a current flows in a In electrolysis process, the
electrons move in the conductor, a magne c field is liquid separates into its
conductor. established around the chemical parts when electric
conductor. current flows through a
The amount of heat generated
conduc ng liquid.
depends on the amount of Magne c field increases with
current flowing and type of increasing current. Alterna vely, if two metals are
conductor material used. placed in a conduc ng liquid
Turning off the current causes
they react chemically and
the magne c field to disappear.
produce electricity.

Fig. 4.1.20 Effects of Current Flow

Fundamental Quan es used in Electrical and Electronic Principles

The table below shows the various terminology, their units, symbols, defini on, and common formulas:

Name Unit name Symb Defini on Common

ol formulae

Electric current Ampere I The number of electrons that I=V/R

pass through a fixed point in one
second.

Electric pressure Volt V A voltage of 1 volt applied to a

or Voltage circuit will produce a current V=IR
flow of 1 amp if the circuit
resistance is 1 Ohm

E l e c t r i c a l Ohm, Ω R It is the opposi on to current

resistance flow in a circuit when a voltage is R=V/I
applied across it.

Electrical charge Coulomb Q One coulomb is the quan ty of

electricity conveyed by a current Q=It
of one ampere in one second.

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Name Unit name Symb Defini on Common

ol formulae

Current density Ampere/sq.m J It is the amount of electric J=I/A

current travelling per unit cross- (A= area)
sec on area.

Conductance Siemens G The ability of a material to carry G=1/R

an electrical current. One
Siemens equals 1 amp per volt.

Resis vity Ohm metre A measure of the ability of a R=ρL/A

material to resist the flow of an where,
electric current.
L= length
A = area

Power Wa W When a voltage of 1 volt causes P=VI

a current of 1 amp to flow the P=I2 R
power developed is 1 wa . P=V2/R

Conduc vity σ It is the reciprocal of resis vity. σ =1/ρ

Capacitance Farad C It is the ability of a system to C=Q/V

store electric charge for a given C=εA/d
poten al difference between where, A = Area
the terminals. of the plates
d= distance
between the
plates
ε= permi vity
of the dielectric

Inductance Henry L It is the property of an electric I=V/R(1- e-Rt/L

conductor or circuit that causes where,
an electromo ve force (emf) to i =
be generated by a change in the instantaneous
current flowing. current
R = resistance
L = inductance
t = me
e = base of
natural logs)

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Name Unit name Symbol Defini on Common formulae

Magne c field Amperes per H Magne c field strength is H= B/μ_0

strength metre one of two ways that the where,
intensity of a magne c
B = magne c flux
field can be expressed.
density
magne c
permeability

Magne c flux Weber φ A measure of the strength Φ= μHA

of a magne c field over a where,
given area. μ = magne c
permeability
H = magne c field
intensity
A = area

M a g n e c fl u x Tesla B It is the force ac ng per B= H/A

density unit current per unit B= μH
length on a wire placed at
right angles to the
magne c field.

Table 4.1.4 Electrical and Electronic parameters

Electrical Circuits
When an electromo ve force or voltage is applied to a conductor, a direc onal movement of electrons
will take place. For example: when a ba ery is connected to a wire, then the source will be the ba ery
and the wire is the conduc ng path in which the electrons move. The flow of electrons is called electric
current.
The diagram below shows a simple electric circuit:

Switch

Fig. 4.1.21 Simple Electric Circuit

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In the above circuit, the ba ery posi ve terminal is connected to a switch, lamp, and the ba ery
nega ve terminal.
The two types of electrical circuits are Open and Closed Circuits.
A switch in the open posi on disconnects the light bulb from the ba ery, crea ng an open circuit.
Turning the flashlight on by sliding the black bu on to the le pushes the two pieces of metal together
— or closes the switch — and completes the circuit so that current can flow

Open Circuit Closed Circuit

When the switch is When the switch is

open, the circuit is closed, circuit is
broken and no current complete and current
can flow. can flow through it
when a voltage is
applied.

Fig. 4.1.22 Open and Closed Circuit

Short circuit
A short circuit is an electrical circuit that allows a current to travel along an unintended path with no or
very low electrical impedance. This results in an excessive current flowing through the circuit.
High resistance
High resistance means a part of the circuit has developed a high resistance which will reduce the amount
of current that can flow. For example, a dirty connec on.
Conductors, Insulators, and Semiconductors
Conductors are those materials in which the electrons can move easily. All metals are conductors, for
example, gold, silver, copper, aluminium, etc. Liquids that conduct electric currents are called
electrolytes.
Insulators are those materials in which the electrons are difficult to move. These are generally non-
metallic materials like wood, plas c, rubber, glass, etc.
Semiconductors are those materials that can act either as conductors or insulators. Pure elements like
silicon and germanium are examples of semiconductors. They are used in the produc on of diodes and
transistors.

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The resistance offered by a conductor depends on the following factors:

Length – longer the length of the conductor, higher the resistance.

Cross-sec onal area – larger the cross-sec onal area, smaller the resistance.

Temperature – in most metals as the temperature increases, the resistance also

increases.

Type of material – conductors made from different materials exhibit different resistance, it is
known as specific resistance of the material.

Fig. 4.1.23 Factors Affec ng Resistance of a Conductor

Resistors
Resistors are used to control the current flow in a circuit or to set voltage levels. Good conductors have
low resistance; therefore, they are used to carry the current with minimal voltage loss. Resistors are
made with materials that have high resistance.
Circuit networks
Series circuit
All components are connected end to end forming a single path for the current flow. The tail of one
component is connected to the other component’s head, and it has a single pathway if one component
stops working, the complete circuit stops working.

Fig. 4.1.24 Series Circuit

The following rules apply for a series circuit:

Current The amount of current is the same through all the components.

Resistance The total resistance is equal to the sum of the individual resistance.

Voltage
The supply voltage is equal to the sum of the individual voltage drops.
Fig. 4.1.25 Characteris cs of Series Circuit

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Parallel circuit
All components are connected across each other forming mul ple paths for the current flow.

Fig. 4.1.26 Parallel Circuit

The following rules apply to a parallel circuit:

The total circuit current is equal to the sum of current flowing in

Current
each branch.

The reciprocals of individual resistances are added and then the

Resistance reciprocal of the sum is taken to find the resistance. Therefore,
this diminishes the total resistance.

Voltage The voltage is equal across all components.

Fig. 4.1.27 Characteris cs of Parallel Circuit

Magne sm and Electromagne sm

Magne sm can be created by a permanent magnet or by an electromagnet. A magne c field is the space
around a magnet in which a magne c field can be detected. The movement of electric charges causes
magne sm. It is the class of substan al elements facilitated by magne c fields. Each substance is
created of ny units called atoms. And each atom has electrons, par cles that transmit electric charges.
Electric currents and the magne c moments of elementary par cles create a magne c field, which acts
on other currents and magne c moments.
Every magnet has two poles- the North Pole and the South Pole.
• Similar poles repel each other (North-North, South-South)
• Opposite poles a ract each other (North-South, South-North)

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Opposite poles a ract each other

Similar poles repel each other

4.1.28 Rules of Magne sm

Electromagne sm
Electricity and magne sm are related phenomena. If an electric current flows in a conduc ng wire
wound around a so iron core, it creates a magnet. When the current is switched off, the magne c field
disappears. Such a magnet is called an electromagnet. The strength of the magne c field depends on
the amount of current flowing. Force on a current-carrying conductor in a magne c field is caused
because of two magne c fields interac ng. This is the basic principle of how a motor works.
Electromagnets are used in motors, relays, and fuel injectors, to name just a few applica ons.

Fig. 4.1.29 Electromagnet

Electromagne c induc on
Conversely, moving a magnet near a conduc ng wire generates a current in the wire. This phenomenon
is called electromagne c induc on. The direc on of the induced voltage depends on the direc on of the
magne c field and the direc on in which the field moves rela ve to the conductor. The voltage level is
propor onal to the rate at which the conductor is cut by the magne sm. Electromagne c induc on is
the basis on which a generator works. A generator is a machine that converts mechanical energy into
electrical energy.

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Fig. 4.1.30 Electromagne c induc on

Mutual induc on
If two coils known as primary and secondary coils are wound onto the same iron core, then any change in
magne sm of one coil will induce a voltage in the other. This can be achieved by switching on and off the
current to the primary coil. If the number of turns of wire on the secondary coil is less than the primary
coil, then a lower voltage is obtained. If the number of turns of wire on the secondary coil is more than
the primary coil, then a higher voltage is obtained. The value of the voltage depends on the primary
current, the turns ra o between the primary, and secondary coils, and the speed at which the
magne sm changes. This is known as ‘transformer ac on’. It is the principle of the igni on coil. DC-DC
converter works on the mutual induc on principle.

Defini ons and Laws Related to Electricity

Ohm’s Law
Ohm’s law states that the current (I) in an electric circuit is inversely propor onal to the resistance (R) of
the circuit when voltage (V is constant).

V V
V=IR or R= or I
I R

Where, I = Current in amps, V = Voltage in Volts and, R = Resistance in Ohms.

Lenz’s law
Lenz’s law states that the current (Electromagne c Force, EMF) induced in the circuit flows in a direc on
such that the current opposes the change that induced it. This law gives the direc on of the induced
EMF resul ng from electromagne c induc on and the opposing EMF is known as back EMF.

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Kirchhoff’s laws
Kirchhoff’s 1 law
The current flowing into a node (junc on) in a circuit must equal the current flowing out of the node
(junc on). It means that no charge can be lost in a node (junc on) and any charge that flows in must flow
out, therefore, it is the direct result of the conserva on of charge.
Kirchhoff’s 2ⁿ law
“The sum of the products of electric currents and corresponding resistances flowing in different parts of
a closed circuit is equal to the sum of the total electric carrying forces present in that circuit." This is the
same as the series circuit, i.e., the sum of all voltage drops will always equal the supply voltage.
Faraday’s law
According to Faraday’s law, changes in the magne c field around the coil of wire will induce an EMF
(voltage) in the coil. The change produced and the voltage generated could be achieved:
• By changing the magne c field strength
• By moving the magne c field towards or away from the coil
• By moving the coil in and out of the magne c field
• By rota ng the coil in rela on to the magne c field, etc.
Fleming’s law
When a current-carrying conductor is placed underneath a magne c flux, a force acts on the conductor.
The direc on of this force can be related to Fleming’s Le -Hand Rule. Likewise, if a moving conductor is
brought underneath a magne c flux, an electrical phenomenon is elicited in this conductor. The
direc on of the elicited current is related with Fleming’s Right-Hand Rule.
Fleming’s rules are used to determine the direc on of mo on or direc on of induced current
• The first finger indicates the Magne c field, the second finger indicates the Current, and the thumb
indicates the Mo on.
• Fleming’s rules show the direc on of the magne c field, mo on, and current in electrical machines.

Right Hand rule used for Generators Le Hand rule used for Motors

Fig 4.1.32 Fleming’s Law

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Ampere’s law
Ampere's Law states that for any closed loop path, the sum of the length elements mes the magne c
field in the direc on of the length element is equal to the permeability mes the electric current
enclosed in the loop.
Ampere's Law allows us to bridge the gap between electricity and magne sm; that is, it provides us with
a mathema cal rela on between magne c fields and electric currents. It gives us a way to calculate the
magne c field that is produced as a result of an electric current moving through a wire of any shape.
Electronic Components and Principles Used in Evs
Electronic components and circuits are used in a range of applica ons in EVs. There are various symbols,
units, and terms used in the wiring diagrams of electrical and electronic circuits. These are universal
conven ons used across all industries worldwide.
The table below consists of the symbols of various components used in electrical and electronic circuits:

Symbol Name of component

DC voltage source (Ba ery)

AC voltage source

Solar Cell

Current source

Fuse

Microphone

Loudspeaker

Buzzer

Hea ng element

Resistor

Variable resistor

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Symbol Name of component

Poten ometer

Light-dependent resistor

Capacitor

Polarised capacitor

Pre-set adjustment

Inductor

Inductor with magne c core

Transformer

Aerial

Generator

Motor

Ammeter

Voltmeter

Oscilloscope

Thermistor

Single junc on

Double junc on

Diode

Light-emi ng diode

Breakdown diode

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Symbol Name of component

General ground

Chassis ground

Switch

Relay coil

Break contact

Lamp or light

AND gate

NAND gate (Not-AND)

OR gate

NOR gate

XOR gate (Exclusive-OR gate)

Inverter (Not gate)

RS-bistable

Opera onal amplifier

Table 4.1.5 Symbols of Electrical and Electronic Components

Resistors are devices having resistance to the passage of an electric current. Resistors are chosen based
on the ohms value and power ra ng and are used to limit current flow and fixed voltage drops.
Capacitors are devices used to store an electric charge, consis ng of one or more pairs of conductors
separated by an insulator. They can be described as two plates separated by a dielectric. Metal foil
sheets rolled up together with a type of paper for insula on placed inside a n can is used to make
capacitors. The value of the capacitance is dependent on the area of the plates, the distance between
the plates, and the permi vity of the dielectric. In vehicles, they are used for reducing arcing across
contacts, electronic control units, and radio interference suppression circuits. Variable capacitors can be
made by changing any of the variables men oned above.
A circuit has a capacitance of one farad (F) when the charge stored is one coulomb and the poten al
difference is 1 V.

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Inductors are components that store energy in the form of a magne c field. It consists of a coil of wire
wound on a former placed in a can. The magne c effect of the changes in the current flow introduces
inductance. They are used in oscillator and amplifier circuits. Inductors known as chokes are useful for
tuning a circuit and are used in DC circuits to smooth the voltage. The unit of inductance is henry (H) and
a circuit has an inductance of 1H when a current, changing at one ampere per second, induces an emf of
1V in it.
Diodes are known as one-way valves. A diode is a simple PN junc on allowing electron flow from the N-
type material (nega vely biased) to the P-type material (posi vely biased). Zener diodes are designed to
break down and conduct in the reverse direc on at a predetermined voltage. Diodes are made from
doped silicon.
Transistors are used as either a solid-state switch or as an amplifier. Transistors are constructed from the
P- and N-type semiconductor materials (the same as in diodes) and can be either made in NPN or PNP
format. The three terminals are known as the base, collector, and emi er. The circuit between the
collector and emi er will conduct when the base is supplied with the correct bias. The amplifica on
factor-β of the device is indicated by the ra o of the current flowing through the base compared with the
current flowing through the emi er, (β=I)_e/I_b.
Field-effect Transistors (FETs) are constructed in their basic form as P-channel or N-channel devices. The
three terminals in FET are known as gate, source, and drain. The voltage on the gate terminal controls
the conductance of the circuit between the source and the drain.
Insulated Gate Bipolar Transistor (IGBT) is a three-terminal power semiconductor device used for
switching electric power in EVs, air-condi oners, stereo systems with switching amplifiers, etc.
Metal oxide Semiconductor Field-effect Transistor (MOSFET) are used as switching devices in inverters
as they are extremely fast, thus, reducing switching losses. It only requires a small gate current to
func on. They are considered as ideal switches and are used in DC-DC converters, low voltage motor
controllers, power supplies, etc.
Integrated circuit is a set of electronic circuits on a small flat piece of semiconductor material (a chip). In
an integrated circuit, electronic components can be combined to carry out various tasks such as
switching, amplifying and logic func ons. It can therefore be defined as a semiconductor on which
millions of ny resistors, capacitors, transistors and diodes are fabricated. There are different types and
ranges of integrated circuits available for almost any applica on.
Electrical and Electronic Signals
Electrical input and output
Electrical input refers to the amount of energy put into a device and electrical output refers to the
amount of energy that comes out of a device. A device can change the type of energy output but not the
quan ty. For example, the input energy for a light bulb is electrical energy and its output is light and
heat.

Device

Input Output

Fig. 4.1.33 Electrical input and out output

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Pulse width modula on

It is a method used to reduce the average power delivered by an electrical signal, by effec vely chopping
it up into discrete parts. The average value of voltage (and current) fed to the load is controlled by
turning the switch between supply and load on and off at a fast rate. If the switch is on for longer periods
compared to the off periods, then higher the total power supplied to the load.

Narrow Wide
Pulse Pulse

High Average
Voltage
Low Average
Voltage

Fig. 4.1.34 Pulse width modula on (Source: electronics-tutorials.ws)

Analog signals
Analog signals are con nuous in both values and me and are bound within a certain range. For
example, +24V to -24V. In an electrical signal voltage, the current, or frequency of the signal may be
varied to represent the data.

Fig. 4.1.35 Analog Signals

Digital signals
They represent data as a sequence of discrete values, for example, values like 3.4V or 6V, etc. Digital
signals must have a finite set of values. They are used in digital electronics like data transmission devices
and compu ng equipment.

Fig. 4.1.36 Digital Signals (Source: www.monolithicpower.com)

Fiber-op c communica on
It is a way of transmi ng informa on from one place to another by sending pulses of infrared light
through an op cal fiber. Light is a form of the carrier wave that is modulated to carry informa on.

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4.1.6 Basics of EV Anatomy

An Electric Vehicle is composed of many parts/components and subsystems. The major EV subsystems
can be categorised into four groups:

EV Anatomy

Body design Energy source Electric propulsion Auxiliaries

Ba eries Control unit Brakes

Body structure
Ba ery charger Power converter Steering
Frame Electric motor
Energy management Suspension
Bumpers Transmission
Cooling system Wheels Temperature control

Fig. 4.1.37 EV Anatomy

Ba ery Pack
The complete ba ery pack consists of a number of cell modules, insula on, a cooling system, junc on
box, ba ery management, and a casing. The most common ba ery technology used is lithium-ion. The
ba ery is usually located on the floor-board of a scooter or the underbody of a car. The capacity of a

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ba ery is given in terms of Amp-H (generally for two-wheelers) or kilowa -hours (KWH). The different
types of ba eries are:

Lead-acid ba eries: This Nickel-metal hydride Lithium-ion ba eries:

type of ba ery is best (NiMH) ba eries are These ba eries are the
suited for low-voltage used in electric vehicles. most popular choice in
motor vehicles. A 12V lead- The energy density of BEVs and HEVs. They
acid ba ery consists of six NiMH ba eries is more have high energy density
cells connected in series. than two mes that of a and low self-discharge.
Each cell will be housed in lead-acid ba ery but less They can be easily
individual compartment than lithium-ion charged and have low
and produces about 2V. ba eries. Their maintenance cost. These
They have a short life and maintenance cost is high. ba eries can be a safety
therefore used as a They are more effec ve hazard since they contain
secondary storage for in HEVS and less effec ve flammable electrolytes
commercial vehicles and in BEVS. and if they are charged
not used as a main ba ery Picture Source incorrectly or damaged it
in Evs www.toyota.com. can explode and cause
Picture Source fires.
www.electricalacademia.co Picture Source
m www.nissan-global.com.

Fig. 4.1.38 Types of Ba ery

The most commonly used ba ery in EVs is lithium-ion. The ba ery pack consists of:
• Case faceplate
• Several cell modules (100–300 cells)
• A cooling system
• Insula on
• Ba ery junc on box
• Ba ery management controller
• A suitable case or shell
These features combine so that the pack can withstand extreme temperatures and their impacts. The
ba ery is generally installed in the underbody of the car. These ba eries are specifically designed for a
high ampere-hour (or kilowa -hour) capacity and is around 20-25 kWh. In a pure EV, the ba ery can
weigh more than 300 kg. The typical voltage of a ba ery is around 300V and some mes can be up to
650V.

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Electric Motor/Generator
Motor converts electrical energy into kine c energy (or movement), which moves the vehicle. Electric
motors used in EV can be broadly categorised as AC and DC motors. The desirable features in an EV
motor are:

Quick torque response

High power density

High instant power

High efficiency

Low cost

High accelera on

Fig. 4.1.39 Desirable features in EV Motor

The different types of motors used in EV are classified as:

EV Motors

DC Motors AC Motors

Permanent
DC Brushed Brushless DC Magnet
Induc on Motors
Motors (BLDC) Motors Synchonous Motor
(PMSM)

Fig. 4.1.40 Types of Motors

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DC motors allow simple control and are robust. A DC motor is a rotary electrical motor that converts DC
electrical energy into mechanical energy. The most common types rely on the forces produced by
magne c fields.
They can be further classified as DC brushed and brushless motors.

Brushed DC motor Brushless DC (BLDC) motor

Comprises of a fixed stator made of a Comprises of a stator made up of coils
permanent magent and a rotor (moving and a rotor made up of a permanent
armature) on which commutator, magnet. the motor sha is a ached to
brushes and a split ring are placed the rotor. Brushes are replaced by
around the motor sha . electronic compoents.
Advantages are easy speed control, low Advantages are high efficiency, less
cost and high torque at low speed. maintenance and longer life than
brushed DC motors.
Disadvantages are large size, frequent
maintenance and low efficiency. Disadvantages are more expensive.
They are used in railways. They are used in electric two-wheelers
and electric three-wheelers.

Fig. 4.1.41 Types of DC Motors

AC motors in general have high efficiency, high reliability, less maintenance, and good regenera ve
capability. AC motor is a three-phase motor that has a speed feature of running at 240V. Its regenera ve
feature can also work as a generator that brings back power to the ba ery of an EV.
Electric vehicles with AC motors can get a be er grip on uneven landscapes and run more smoothly. It
also has more accelera on.

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The two types of AC motors used in EVs are:

AC Induc on motors Permanent Magnet Synchronous Motor

Comprises of a three-phase winding (PMSM):
distributed around a laminated stator Their construc on is similar to BLDC,
which sets up a rota ng magne c field, and have permanent magnets in rotor.
that the rotor follows. Most commonly Advantages are simple construc on,
used in EVs because of its benefits. high efficiency and high-power density.
Advantages are simple construc on, Disadvantages are high costs, lower
robustness, low cost, high reliability and reliability because of possible breaking
simple maintenance. of magnets and eddy current loss at high
Disadvantages are low power factor, speed.
higher power losses and slightly lower They are used in EVs, hybrid vehicles and
efficiency. heavy electric vehicles.
They are used in electric two-wheelers
and four-wheelers

Fig. 4.1.42 Types of AC Motors

DC-AC Converter (Invertor)

Fig. 4.1.43 Inverter (Source: www.bosch-mobility-solu ons.com)

It is an electronic device which changes Direct Current (DC) from ba ery to Alterna ng Current (AC) to
drive the motor. It does this reverse to regenerate charging. A 3-phase inverter converts DC-input to 3-
phase AC-output with the help of three arms normally delayed by an angle of 120 degrees.

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On-Board Charger (OBC)

Fig. 4.1.44 On-Board Charger (Source: www.electraev.com)

OBC is used to charge the rechargeable ba ery in electric vehicles. It converts AC input from the grid to a
DC input which charges the ba ery. In EVs, the converter is built inside the car. This is the most common
charging method for electric vehicles and most chargers use AC power.
The primary DC to DC converter changes DC power from an on-board 48-800V high voltage ba ery into
lower DC voltages (12V) to power headlights, interior lights, wiper, and window motors, fans, pumps,
and many other systems within electric vehicles (EV)
Ba ery Management System (BMS)

Fig. 4.1.45 Ba ery pack (Source: Volkswagen)

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It monitors and controls the ba ery and determines the state of charge of the cells. It regulates the
temperature of the ba ery and protects the cells from overcharging and deep discharge. Electronically
ac vated switches disconnect the ba ery system when idle and in situa ons of a fire incident or
accidents. Typical func ons of the BMS system are:
• Cell Monitoring
• Power Op miza on
• Safety of Electric Vehicle
• Ba ery Charging Op miza on
Control Unit
A control unit is also known as the power control unit or motor control unit, the electronic device
controls the power electronics (inverter). It responds to signals from the driver (brake, accelera on, etc.)
and causes the power electronics to be switched accordingly. The control makes the motor drive the car
or become a generator and charge the ba ery. It can also be responsible for air condi oning, PAS, and
brakes.
Thermal Management System
When due to the opera ons of the DC-DC converter, power electronics, and ba ery
charging/discharging cycles. Liquid cooling systems are used to cope with high-voltage, high-rate
charging, and greater ba ery density and also allow use of waste heat. Electro-thermal recuperator
(ETR) is a liquid cooling system used for Pure EVs.
Heat pumps are used to transfer heat energy from a source of heat to a thermal reservoir, which moves
the thermal energy in the opposite direc on of heat transfer. The heat pumps work in the exact opposite
manner to that of a car AC system. The medium for heat transfer is a refrigerant. Heat pumps have a
condenser, expansion valve, evaporator, and compressor. They can be used both in cooling and hea ng
mode.
Charging Unit and Charging Systems

Fig. 4.1.46 Charging unit

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It is used in BEV (ba ery electric vehicles) and PHEVs (plug-in hybrid vehicles). It converts and controls
the mains voltage (230V in India) to a suitable level for charging the ba ery cells (typically 300V DC).
The charging system supplies electricity to all the electrical devices and charges the ba ery. It is an
integral part of the electrical system. It provides electrical current for the lights, radio, heater, drive
motor, and other electrical accessories. It also charges the ba eries during brake regenera on
condi ons.
Three broad categories of EV charging infrastructure:
• Alternate-current (AC) charging
• DC charging
• Wireless charging
The charging unit is used on pure EVs and is usually located near where the external power source is
connected. It converts and controls the ‘mains’ voltage to a suitable level for charging the ba ery cells.
AC Plug Connector
It uses an AC charger installed at a charging sta on or at home. It is the most flexible method and
charging is possible on household sockets. Domes c charging may take several hours due to limited
power through the socket, it also depends on the ba ery capacity, fill level, and charging current. When
the vehicle is charged at a charging sta on, the charging me is reduced considerably.

IEC 60309 Industrial socket used by IEC 62196 Type 2 connector used by
Indian e-rickshaws, Mahindra e2o, Indian and Global EVs, electric cars,
Mahindra e2o Plus P6. Mahindra e2o Plus P8., Nissan Leaf, etc.

Simple 3 pin connector coupled with a

15 Amp plug used in Indian e-Scooters.

Fig. 4.1.47 Types of AC Plug Connectors

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DC Plug Connector
It uses a DC charger at the charging sta on and they are much more expensive than AC charging sta ons.
The infrastructure required for this type of charging is more elaborate with an appropriate network of
charging sta ons and high-power requirements.

CHAdeMO connector CCS connector

GB/T connector

Fig. 4.1.48 Types of DC Plug Connectors

Trickle Charging Connector

It uses a household current for charging. It is the slowest charging op on.

Fig. 4.1.49 Trickle Charging Connector

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Wireless or Induc ve Charging

In this type of charging no physical connec on is made, the principle of mutual induc on or transformer
ac on is used.
Hea ng, Ven la ng, and Air-condi oning (HVAC)
HVAC is the indoor unit of a car air-condi oner with a heater and air condi oning func on. The
opera on of hea ng and cooling can happen when the vehicle is plugged in and charging and also
directly from the ba ery. If the vehicle can be heated or cooled (pre-condi oned) during charging on
mains power, it can save ba ery capacity and increase the range. The two systems that can be used are
cooling with an electrically driven air condi oner compressor and hea ng with a high-voltage posi ve
temperature coefficient (PTC) heater. These high-voltage components can be ac vated with a mer or
remote app. The air condi oning (AC) system provides cooling, hea ng, and ven la on in the cabin of
electric vehicles (Evs). A typical car air condi oning system consists of a compact version of the standard
air condi oner components with an evaporator, compressor, condenser, expansion device, and a fan
fi ed in a car to provide air-condi oning inside the vehicle.
Brakes
In EVs, an electrically assisted master cylinder is used to sense the braking pressure applied by the driver.
The signals from the master cylinder sensors are sent to the control unit. The control unit in turn
switches the motor to regenera ve mode causing the ba eries to charge and retarda on or
regenera ve braking. For further braking, hydraulic brakes are operated with electrical assistance if
required.

Fig. 4.1.50 Brake Master Cylinder (Source: Electric Vehicle Technology)

Types of Brakes

Drum Brakes or Internal Expanding Brakes Disc Brake or External Contrac ng Brakes:
These are used as rear brakes to u lize the fric on In this type of braking system, instead of a drum
between the drum and the brake shoes to stop the assembly, a disc rotor is a ached to the wheel's
vehicle. It is usually available in light vehicles like hub in such a way so that it can rotate with the
cars and light trucks. These brakes are divided into wheel. This disc rotor is clamped in between the
two shoes, the le -hand shoe is known as a calliper which is rigidly fixed with the knuckle or
primary shoe and the right-hand shoe is known as upright of the vehicle. When brakes are applied
a trailing shoe. Shoes are a ached to the drum. the mechanism contracts the a ached brake
The fric on between shoes and drum creates the shoes, making the fric onal contact with the
braking torque, which helps to reduce the speed rota ng disc rotor and cause the stopping of a
of the drum to stop the vehicle. vehicle. An external contrac ng brake is used for
only parking purposes.

Con nued...

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Power Brake:
Mechanical Brake: This system combines mechanical components to
mul ply the force applied to the brake pedal to
It is an inbuilt mechanical device for absorbing
stop the car. It consists of vacuum booster, master
energy from a moving system. A mechanical brake
cylinder, brake calipers, drum brake, etc. These
is a cable pull system consis ng of rim-like brakes
braking systems are designed to reduce the effort
just arranged in a different way.
required to depress the brake pedal when
stopping a vehicle.

Hydraulic Brake:
A hydraulic braking system transmits brake-pedal
An -lock Braking System:
force to the wheel brakes through pressurized
fluid, conver ng the fluid pressure into valuable This braking System prevents the wheels from
work of braking at the wheels. The brake pedal ge ng locked or skied. The an -lock braking (ABS)
relays the driver’s foot effort to the master- system is a component that ensures passenger
cylinder piston, which compresses the brake fluid. safety by stopping the vehicle in adverse
This fluid pressure is uniformly transferred condi ons, like stopping very quickly or if the road
throughout the fluid to the front disc-caliper is slippery. To simplify it, the ABS prevents the
pistons and the rear wheel-cylinder pistons. The vehicle's wheels from locking up and causing the
pressure on a liquid is called hydraulic pressure. vehicle to skid out of control
The brakes which are operated by means of
hydraulic pressure are called hydraulic brakes.

Fig 4.1.51 Types of Brakes

Steering System
A drive motor is used to directly assist with the steering via an epicyclic gear train. An op cal torque
sensor is used to measure the driver’s effort on the steering. This informa on is processed by an
electronic control system that calculates the torque and the steering angle. It helps the driver to control
and turn the vehicle.

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Fig. 4.1.52 Steering System (Source: www.slideshare.net)

Various Parts of Steering System

The various parts of a steering system are:

• A steering linkage is the part of an automo ve steering system that

Steering Linkages connects to the front wheels

• It is made of polyurethane or hard plas c. It consists of a circular rim

with a hub at the center. The rim is slightly ellip cal in cross-sec on
Steering Wheel to maintain strength and provide a hand grip. The steering sha is
mated in the undula ons cut on the inside of the steering wheel
hub.

• It is tubular in shape device intended primarily for connec ng the

steering wheel to the steering mechanism. Switches for light, and
Steering Column wiper for easy and quick opera on. The collapsible columns are
used for safety, collapsing upon impact and reducing the chances of
injury to the driver.

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• It is made from drop forged alloy steel. It connects the steering

Steering Sha wheel to the steering gearbox and transfers movements of the
steering wheel to the steering gear or the pinion.

Drop Arm • It is also called as pitmen's arm. It is created of drop forged steel. It
connects the cross sha with the draglink.

• It connects the drop arm to the steering knuckle. It is also made up

Draglink of drop forged steel. The e rod ends are different parts of the
steering linkage connected to the ball joints that provide angular
mo on to the steering system.

4.1.53 Various Parts of a Steering System

Suspension
The suspension system consists of springs, shock absorbers, and linkages that connect a vehicle to the
wheels. It helps in vehicle’s road-holding, braking, providing comfort, reducing stress on the vehicle due
to road shocks, and providing the required height to the vehicle.

Fig. 4.1.54 Suspension System (Source: www.in.pininterest.com)

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Various Parts of Suspension System

The various parts of a steering system are categorized as:

Leaf Springs are curved instructure and the curvature helps the
spring absorb impact.

Coil springs or compression springs. They stock energy and release

it to absorb shock or maintain a force between two contac ng
surfaces.
Types of Spring

Rubber Spring stores more energy per unit mass than any other type
of spring material. It is installed between the frame and the top link of
the suspension system. When it is linked to a point near the link pivot,
deflec on of the spring reduces to a minimum without affec ng the
total wheel movement.

Torsion Bars can be helical or spiral. They are used in automobile

vehicles for transmi ng torque.

Fig. 4.1.55 Types of Spring

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Shock Absorber is a device designed to absorb shock impulses. This

device is also used for checking or damping out the suspension
spring to a comfort level.
Shock Absorbers

Telescopic Fork Absorber is a telescopic fork is a form of motorcycle

front suspension whose use is so common that it is virtually
universal. The telescopic fork uses fork tubes and sliders that contain
springs and dampers.

Fig 4.1.56 Shock Absorber

Drivetrain
The main func on of the drivetrain is to deliver the power generated by the engine (in case of hybrid
vehicles) and motor to the drive wheels. It consists of engine (Hybrid vehicles), motor/motors, torque
converter, transmission, propeller sha , differen al, and axles.

Fig. 4.1.57 Drivetrain in EV (Source: www.evreporter.com)

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Wheel and Tyres

The wheels of a vehicle are mounted on a hub and consists of the rim, tyre, and tube. It helps in
suppor ng the weight of the vehicle, absorbs road shocks, grip the road surface, and balance the vehicle
in mo on, and rest.

Fig. 4.1.58 EV Chassis with wheels and tyres (Source: www.wired.co.uk)

Rim is the outer edge of a wheel that helps to hold the tyre. It provides the outer circular design of the
wheel. Based on that inside edge of the tyre is mounted on vehicles. For example, on a scooter wheel,
the rim is a large hoop a ached to the outer ends of the wheel's spokes that holds the tyre and the tube.
Tyres are mounted on the wheel rim. It provides good grip, carries the load of the vehicle, absorbs road
shocks, reduces vibra ons and gives cushioning effect to the vehicle. It must produce minimum noise,
while the wheel turns on the road. It resists the tendency for the vehicle to oversteer. Tyres’ good grip is
required on both dry and wet roads while accelera ng and braking the vehicle.
Tube tyres consists of a tube between the rim and the tyre, in which air is filled. It is used in most of the
vehicles seen on the road.
Tubeless tyres- Nowadays, with the advancements in technology, tubeless tyres are replacing tube
tyres. Tubeless tyres are mainly used in modern cars. The benefits of tubeless tyres include slow air
leakage during punctures, be er balancing of wheels, low cost, and ease of puncture repairing

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Chassis and Body

Chassis is the load-bearing vehicle frame on which the body of the vehicle, drive motor, transmission
system, and control system (steering, suspension system, brakes) are mounted.
Body is the super-structure of a vehicle and a ached to the chassis. It consists of windows, doors,
bonnet, mud guards, side panels, etc.

Fig. 4.1.59 Body of Hyundai Car

h ps://cdn.automote.co.nz/4/87/g48rbNMj-bFOnFW.jpg

Telema cs
Telema cs systems make the vehicle smart. They combine naviga on, safety, security, and
communica on into the car’s dashboard. Automo ve telema cs systems receive wireless informa on
and transmit it through a crash-resistant box. With telema cs implemented in an EV, an accurate system
of measurement is possible. Real-world data can be monitored and recorded to make well-informed
decisions and not rely on general assump ons. Telema cs systems tradi onally allow drivers to access
services while they are in transit, but now smartphone apps for the systems let owners remotely control
features while they are away from the car.

Naviga on and Tracking System

• It provides the real- me loca on of EV vehicles on a digital map. This naviga on system works
on GPS, which helps track the loca on of the vehicle. This map helps get the real- me traffic
situa on on the road to set the best route to the des na on to save average energy
consump on with a reduc on in total distance traveled. The pathfinding system of telema cs
calculates the distance a vehicle will travel and provides analysis on the required charging for
ba eries while recommending a travel route that has a charging sta on available for recharge.

Con nued...

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Charging Methods

• The telema cs system automa cally sends the charging spot request to the nearest sta on to
check, if they can fulfil the requirement on top of the previously scheduled charging spots. Also,
the system displays the vehicle’s state of charge (SOC), thus helping the user to plan trips
accordingly.

Driving Analysis

• EV telema cs gathers the data from DTG (Digital Tachometer Graph) and GPS to depict the
vehicle's state in terms of distance travelled, me taken, over speeding during the journey,
malfunc oning, records the excep onal events, and warnings. Comparing the driving analysis
data refines the result for be er route op miza on and alerts on exceeding the driving speed
limit and vehicle services status.

Fig. 4.1.60 Benefits of EV Telema cs:

Mul -media and Infotainment

The mul -media interface system is a user interface media system inside the cars, consis ng of a single
integrated interface and can control various devices and func ons of the vehicle. The system consists of
the media terminal and the display screen. The central element of the mul -media interface terminal is
the control dial. This dial can be rotated to navigate up and down through menus and pressed to ac vate
a selected highlighted func on. These mul media systems help in showing maps, connec ng to the
blue-tooth of the user’s phone and also helps in playing music, etc. It also comes with touch
infotainment systems that can provide easy touch opera ons, front and back parking cameras and
video playback features.
Ac ve and Passive Safety Systems
Passive safety systems in vehicles refer to those provisions that come into ac on in an accident and are
intended to safeguard occupant safety. Examples of passive safety systems are ac ve headrests,
seatbelts pre-tensioners, control module, sensors, air-bags, etc.
Ac ve safety systems refer to those systems which assist the driver in avoiding accidents proac vely,
rather than relying on safety equipment. Example of ac ve safety system is An -lock Braking System.
Interconnec ons between Various Components in Electric vehicles
When an EV is started, the ba ery supplies electrical energy to the stator, which is the sta onary part of
the motor’s rotary system. When it receives electrical energy, the stator's coils are powered and create
rota ng magne c fields that rotates the rotor. This mechanical energy turns on the gears which then
rotates the wheels of the electric vehicle.

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The following figure represents the interconnec on between the mechanical and electrical system of
an EV:

Fig 4.1.61 Interconnec ons between Mechanical and Electrical System

The following figure shows the generic block diagram of a BEV:

Fig. 4.1.62 Generic Block Diagram of BEV

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The following figure shows the generic block diagram of a PHEV:

Fig. 4.1.63 Generic Block Diagram of PHEV

The following figure shows the generic block diagram of a PHEV:

Fig. 4.1.64 Generic Block Diagram of HEV

(Images recreated from original source: Electric and Hybrid Vehicles, Tom Denton, Published by
Taylor and Francis)

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Unit 4.2 Prepare to Carry out Rou ne Service or Minor Repair

Unit Objec ve
At the end of the unit, the trainee will be able to:
1. Discuss the importance of no HV (High Voltage) ac vity is being conducted around worksta on prior
to commencement of work.
2. Elucidate SOP for receiving vehicles, opening job card, alloca on of work, invoicing, vehicle delivery,
handling complaints, etc.
3. Discuss standard schedules and checklists recommended by the OEM/auto component
manufacturer for servicing of electric vehicles.

4.2.1 Avoiding HV ac vity around worksta on prior to

commencement of work
It is important to ensure that no HV ac vity is conducted around the area of the worksta on because,
even a er isola on, HV components like ba eries, motors and other components may s ll contain large
amounts of high voltage and energy. Even some electronic components carry dangerous amounts of
electricity even when the ba ery is isolated and the vehicle is switched off. Accidents like collisions may
take place because of residual energy stored in some components. Whenever work requires high
temperatures, ba ery packs and other components suscep ble to damage or explosion should be well
insulated.
Handling of HV systems
The voltages (AC/DC) used on electric vehicles can be lethal if not dealt with precau ons and care. So,
any high voltage (HV) electrical system requires proper training to ensure the safety of the people
working on the shop floor. All high voltage electrical systems should be handled only by trained
personnel wearing proper PPE and by all the precau onary measures. Generally, in EV workshops low
voltage means 12V -24V, and high voltage means over 60V DC. Typically, electric two-wheelers and 3-
wheelers fall in the range of 24V to 72V, electric four-wheelers fall in the range of 300V to 500V and
electric buses range from 800V to 1200V.

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Some of the high voltage components in an EV are:

Ba ery pack

BMS

Electric motor

DC-DC converter

DC-AC inverter

On-board Charger

Main relay

Power relay assembly

HV junc on box assembly

Service plug

Power cables

PTC heater

Compressor

Main fuse

Charging port

Electronic power control unit (EPCU)

Fig. 4.2.1 HV Components in EV

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4.2.2 EV Service Process

It involves the steps to be followed from the me of service booking to ge ng feedback from customers
to follow-up a er EV servicing. The figure below shows the flow-chart of the en re process:

Receive Vehicle
Service Booking Open Job Card Allocate the Work
in Workshop

Pre-servicing Prepare Invoice and

Work as per SOP Final Inspec on
Inspec on Receive Payment

Feedback and
Vehicle Delivery Follow up

Fig. 4.2.2 Flowchart of EV Service Process

Service booking: Bookings are generally made by the Customer Care Execu ves of the workshop.
Bookings can be taken for free and paid services. Customers have to be informed clearly the terms and
condi ons of servicing while booking. In cases of emergency, appointments are given on a priority basis.
Receiving vehicle in workshop: Most workshops have home pick-up op on of vehicles as per the
appointments. A driver will be allocated to pick-up the vehicle. In some cases, the customers drop-off
the vehicle themselves at the workshop.
Open Job card: The specific service requirement can be learnt from the customer or if it is a rou ne
service, then the job card can be prepared as per the SOP of the organisa on/OEM.

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Job Card

ABC Workshop Vehicle Pick-up Date/Time:_____________

XYZ City Vehicle Delivery Date/Time: ____________
Order No._______________ Date_____________
Vehicle Details:
Customer Details: Vehicle Regn.no. _____________________
Name __________________________ Vehicle Type _________________________
Address ______________________________ Model____________________________
_________________________________________ Serial No.____________________________
City________________ Pincode_______________ Mileage_____________________________
State_______________ Phone no._____________ Manufactured Year___________________
Last Serviced_______________________

Service Assigned to___________________

Date Assigned________ Sign. ___________
Customer Sign. ____________________________
Sl. no. Repair/Services Material Used Time Cost
Required

Schedule Start Stop Total Time

1.

2.

3.

4.

5.

6.

Authorized By______________________________ Total Cost

Fig. 4.2.3 Sample job card

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Allocate the work: As per the work required in the job card, the supervisor hands over the vehicle to the
service technician and gives instruc ons on the work to be carried out.
Pre-service Inspec on: The service technician carries out a preservice inspec on to assess the
problems/faults in the vehicle, seek guidance from seniors required.
Work as per SOP: The Service Technician will carry out the required work as per the SOP provided by the
OEM and organisa on following all the safety regula ons.
Final Inspec on: The vehicle will be tested before handing over to the customer to check if all the faults
are rec fied. A test run is also conducted to check the readiness of the vehicle to be driven on the road.
Once it is tested and approved, it is sent for washing.
Prepare invoice and receive payment: Invoice is prepared which includes the servicing fee, price of all
the consumables like lubricants, grease, etc., and replaced parts. The final price is then communicated
to the customer and the payment is collected before or during the delivery of the vehicle.
Vehicle delivery: Once the payment is made by the customer, it is handed over to the customer and
asked to check if the problems are rec fied.
Feedback and follow up: The customers are either made to fill a feedback form at the me of delivery or
asked to do it online. A follow-up call is made by a member of the service team to check if there are any
problems post servicing of the vehicle.

4.2.4 Standard Checklists and schedules recommended

by OEM
Electric Vehicles require far lesser and frequent maintenance than ICE vehicles. Preven ve maintenance
of EVs helps in avoiding breakdowns and costly repairs and ensures safety. Some of the recommended
maintenance/servicing steps by OEMs include inspec on of tyres wear, and tear, checking tyre pressure,
inspec on and replacement of filters, wheel alignment, windscreen wiper replacement, and brake-fluid
change, etc. Every vehicle has OEM guidelines and all servicing, maintenance, and repairing have to be
done with accordance to the OEM guidelines. This helps in the maintaining quality, consistency, and
performance of the vehicle.
OEMs provide a maintenance/servicing schedule based on a certain meline or based on the mileage
covered by the vehicle for inspec on, servicing, and replacement of parts. The sugges on given by
OEMs is based on informa on gathered through experiments and test runs. The following is an example

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of the maintenance schedule provided to the consumer detailing the kind of maintenance that will be
taken up periodically:

Fig. 4.2.4 Format of Standard Checklist and Schedules Recommended

Notes

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Fig. 4.2.5 VRLA Ba ery Service Matrix Recommended

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Unit 4.3 Perform Rou ne Service or Minor Repair

Unit Objec ve
At the end of the unit, the trainee will be able to:
1. Discuss various sources of informa on available for assessing service and repair requirements of the
vehicle.
2. Elaborate ways to work on the HV systems which do not require isola on, troubleshoo ng and
replacing parts on the ac ve HV system.
3. List the ac vi es need to perform for preparing an EV for fault iden fica on and repairing work.
4. Discuss the symptoms of technical faults, their causes and rec fica on procedures in EV.
5. Discuss the documents to be maintained w.r.t inspec on, troubleshoo ng and diagnosis of faults.

4.3.1 Steps to be Taken Before Commencing Work

Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security has
to be followed. The job card has to be obtained and the work that needs to be done has to be analysed
and understood. All the technical data required should be obtained from OEM manuals and from the
Lead Technician. It is a legal requirement for EV workshops to protect its people and workplace from
poten al risks especially while dealing with High-Voltage components. This can be achieved by carrying
out risk assessment, training of workers in safe work prac ces, and maintain safe work environment.
Some of the key steps to be taken before commencing work:

Correct use of appropriate PPE

Correct use of tools, machines and equipment

Correct ways of handling HV components

Appropriate procedures for servicing, maintenance, repair and diagnos cs

Con nued...

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Follow health and safety measures as per SOP

Carry out all procedures as per OEM

Follow workplace procedures

Fig. 4.3.1 Key Steps to be Taken Before Commencing Work

4.3.2 Various Sources of Technical Informa on

The first source of informa on related to the work to be carried out can be obtained from the job card.
Job cards are used in workshops to send job details to service technicians and get informa on back on
the work. Job cards are made based on customer inputs and ini al inspec on a er receiving the vehicle.
Inspec on is done to see if there are any major damages, problems or issues with the vehicle.
Informa on related to servicing and repair requirements for EV can be obtained from the following
sources as well:

OEMs manuals

OEM cer fied repair programs

Safety data sheets

Workshop manuals

Wiring diagrams

Repair instruc on manuals

Verbal instruc ons from seniors and experienced colleagues

Fig. 4.3.2 Various Sources of Technical Informa on

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4.3.3 De-energiza on process

Manual de-energiza on process
It should be performed only if the OEM specific diagnos c tool is not available.
The process for manually de-energizing HV systems in an EV safely:

Switch off the igni on, remove the key and prevent unauthorized access to it

Setup a barrier around the vehicle (approximately 1 meter away from the vehicle)

Place HV warning signage on the vehicle

Switch off the main ba ery switch and safeguard the main ba ery switch against reconnec on

Remove the nega ve terminal of the ba ery pack and insulate

Secure the bolts in a safe place to prevent short circuit

Unlock the service plug and disconnect it from the HV ba ery pack

Disconnect the charging plug

Remove fuses

Check for non-live state as per OEM instruc ons and also using suitable test apparatus like voltage
testers

Wait for 5-10 minutes to allow storage capacitors to discharge before taking up the work

Ensure that the junc on board terminal voltage is nearly zero Volts

Remove the high voltage cables (HV cables are orange in colour)

Fig. 4.3.3 Manual De-energiza on Process

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De-energiza on process using OEM scan tool

The process for De-energizing HV systems using OEM scan tool in an EV safely:

Refer to OEM manual for the specific methods of de-energizing HV components.

Ensure that the vehicle is parked securely

Connect the diagnos c tester

Select diagnos c mode and start diagnosis

Select test tab and press own test

Select the following components from the menu one a er the other for diagnosis:

• Electrical system
• Electric drive-control unit
• Self-diagnosis compa ble systems
• De-energize HV system

Pull-off the maintenance connector for the HV system

Ensure that the system is de-energized

Secure to prevent reac va on

Fig. 4.3.4 De-energiza on Process using OEM Scan Tool

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4.3.4 Maintenance of EVs

Maintenance is carried out to keep the vehicle in good condi on in respect to its aesthe cs and
func onal performance. There are different types of maintenance as shown below:

Types of
Maintenance

Condi oned Pre-

Preven ve Correc ve Predic ve
based determined

• It is aimed at catching and fixing the problem before they can

Preven ve happen.
Maintenance • The primary benefits of preven ve maintenance are that it can
eliminate unplanned vehicle off road me.

Correc ve • Correc ve maintenance is ini ated when a problem is discovered

Maintenance while the vehicle is being a ended.

• It is considered to be a more advanced alterna ve to preven ve

maintenance.
Condi on Based
• In condi on-based maintenance technician observes the
Maintenance
performance and iden fy variables that could affect the func oning
of vehicle like temperature, speed, power, vibra ons etc.

• This is an advanced version of condi on-based maintenance in

which vehicle / components are a ached via sensors and observed
Predic ve
their real me performance through appropriate so ware.
Maintenance
• So ware interprets the data and warns the technician of
approaching danger.

• It is carried out using rules and sugges ons created by OEMs.

• These sugges ons are based on experiments and gathered data.
Predetermined
• OEMs provide sta s cs and guidelines for average lifespan of its
Maintenance
various parts.
• The OEM will suggest how o en parts should be inspected, serviced
and replaced.

Fig. 4.3.5 Types of Maintenance

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Maintenance Schedules

Fig 4.3.6 Maintenance Schedule

Lubrica on
Moving parts cause fric on which produces a lot of heat, leading to wear and tear on the metal surface.
Metal parts are also prone to corrosion and rus ng. Lubrica on helps preven ng corrosion and in
reducing fric on which in turn reduces wear and tear. Lubrica on is one of the main ac vi es in
maintenance of mechanical parts of vehicles.

4.3.5 Precau ons to Prevent Damage to Other Parts While

Repairing
If proper care is not taken, then the chances of damaging other parts when work is being done on one
part would be very high. The first precau on to be taken is to check which parts are connected to the
part that is being repaired. Therefore, first refer to the OEM manual, wiring diagrams, interconnec ons
of parts, etc. to check the procedures to be followed. For example, removing, and replacing an oil filter
can affect other systems if the oil pressure switch gets disconnected by mistake. More precau ons have
to be taken while dealing with HV components and ba eries. Electromagne c radia on can affect
electronic components and circuits. Therefore, all precau onary measures have to be taken as per the
manufacturer’s guidelines.

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4.3.6 Inspec on of EV Prior to Commencing Work

Visual Inspec on of HV Components and Cables
Whenever any kind of maintenance or repair work is carried out, if proper care is not taken, then work
on one system may affect another system. Especially when work is being carried out on HV components,
connec ons to other systems must be considered. The current draw capability of the vehicle and the
poten al for short circuits and its impact on components should be considered.
Visual Inspec on of HV Cables

Check for defec ve or damaged insula on

Check for external damage or unusual deforma ons

Check for correct rou ng and security

Fig. 4.3.7 Visual Inspec on of HV Cables

Visual Inspec on of Ba ery

Check for cracks/deforma on in upper part of the ba ery housing and tray

Check for colour changes and stains in ba ery housing

Check for electrolyte leakage

Check for corrosion and damage caused by corrosion

Check for fi ed poten al equaliza on line

Fig. 4.3.8 Visual Inspec on of Ba ery

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Visual Inspec on of Engine Compartment Area

Check the condi on of power and control electronics for electric drive

Check HV charging socket for electric drive

Check HV cables for ba ery

Check HV cables for AC compressor

Check HV cables for electric drive

Check HV ba ery and HV cables for ba ery underbody

Fig. 4.3.9 Visual Inspec on of Engine Compartment Area

4.3.7 Remove and Replace Various Components in EVs:

HV Components
The main HV components in an EV can be categorized as follows:
• Ba ery management system
• Power control unit and inverter
• Drive motor/generator
• Power steering
• Charging unit
• HV cables
• AC pump
• Electric heater

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The precau ons to be taken while carrying out HV-related work are as follows:

Wear protec ve gloves

Wear eye protec on

Take precau ons against risks associated with poisonous dust and fluids

Do not work on HV ba eries that have short-circuited

Take precau ons to avoid burns from HV ba eries

Take preven on to avoid severe and fatal injuries due to electric shock

beware that the cooling system will be under pressure when the engine is hot

Fig. 4.3.10 Precau ons to be Taken While Carrying out HV Work

Procedure for Removal and Replacement of HV components

All HV maintenance and replacement work should be carried out by following all the safety procedures
and OEM guidelines.

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The general steps to be followed for the removal of HV components are:

Wear appropriate PPE

Collect all the tools and equipment required

De-energize the system

Drain coolant and other fluids if applicable

Remove covers and housing if any

Remove HV cables and other connec ons

Remove all bolts and nuts

Remove the main component

Fig. 4.3.11 Steps Involved in Removal of HV components

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A er carrying out the maintenance, servicing, or repair work the components have to follow the reverse
order for installa on.
Procedure to Remove Ba ery Pack

Wear appropriate PPE

Collect all the appropriate tools and equipment required

De-energize the system

Remove underbody covers, silencer and heat-shield for ba ery

Open coolant filler cap and keep drip tray under it

Remove poten al equaliza on line

Disconnect HV cables

Fit protec ve cap on to HV connec on

Drain collant a er removing the pipes

Use li assemble pla orm to raise and support the HV ba ery

Remove moun ng bolts and lower the ba ery with the help of the li pal orm.

Fig. 4.3.12 Procedure to Remove Ba ery Pack

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Procedure to Install Ba ery Pack

Follow the steps to remove the ba ery in the reverse order for installa on

Tighten all the bolts to required torque

Pull protec ve cap off HV connec on before connec ng HV cable

Refill coolant

RE-energize HV system

Fig. 4.3.13 Procedure to Install Ba ery Pack

Low-voltage Components in EV
An EV is composed of low-voltage components like mechanical and low-voltage electrical components.
Low-voltage components that require maintenance and replacement are:

Control units

Fuse boxes

Alternator

Central locking

Ligh ng

Starter motor

Electric wipers and windows

Wiring, etc.

Interior hea ng system

Low-voltage components of air-condi oning system

Central locking

Alarm

Fig. 4.3.14 Low-voltage Components in EV

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The following are the steps to be followed while working on non-HV components:

Always refer to OEM instruc on and guidelines regarding safery and processes to work on Evs.

Keep remote opera ons keys away from vehicle to prevent any accidental movement of vehicle or
opera on of electrical systems.

if keys are required while working on the vehicle, the technician should ensure that the vehicle is
secured and in safe condi on before the key is retrieved.

Visual inspec on of HV cables and other electrical components should be checked before star ng
any work.

If the vehicle needs to be energized, isolacte or disconnsct the HV ba ery as per OEM guideleines
and then start work.

Before carrying out opera ons like welding, cu ng or replacement of parts determine the loca on
of all HV cables and components.

Work on live electrical components should be carried out only if there is no other way to work on it.

Fig. 4.3.15 Steps to be Followed while Working on Non-HV Components

Steps Involved in Replacing Electric Components

Switch off and disconnect the main circuit to which it is a ached

Remove the cover

Unscrew the nuts and bolts if applicable

Disconnect the wires

Remove the component

Replace the component a er repairing or place a new component

A ach wires to the replaced components

Close the cover and connect to the main circuit

Test the repalced component

Fig. 4.3.16 Steps Involved in Replacing Electric Components

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Working on Mechanical Components

Wear appropriate PPE

Collect all the tools and equipment required

Ensure all HV cables are dicconnected

Ensure that the workplace is clean and cover the open area with grease-proof paper

Remove all fluid lines and close ith with plus to prevent contamina on and loss of fluid

Remove the parts ensuring cleanliness and mark ma ng parts with ink

Mark parts which require inspec on and further diagnosis

Cover the area where components are removed with plugs

Keep all the parts removed in a tray

Report any damaged or defec ve parts

Carry out the required work on the component

Fig. 4.3.17 Steps to be followed while Working on Mechanical Components

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4.3.8 A er the Comple on of Work

Steps to be followed a er the comple on of work:

All the tools should be cleaned and put in their jackets or tool kits and returned.

If there are any unused spare parts it should be returned to the stores.

All the waste generated should be segregated and disposed in a safe manner as per the company
procedures.

The vehicle has to be re-energized and take for a test-ride.

The vehicle has to be tested with the help of EVSLT for diagnosis of faults.

Document details related to inspec on, servicing and repairs performed.

Fig. 4.3.18 Steps to be followed A er Comple on of Work

Re-energizing the EV A er Comple on of Work

The following steps have to be followed to re-energize the EV:

Use appropriate PPE

Refer to OEM guidelines to re-energize the EV.

Unlock service connector

Replace service connector

Switch-on igni on

Check dashboard warnings

Connect scanner

Check for faults using scanner

Remove guards, fencing and safety signage

Fig. 4.3.19 Steps to Re-energize EV A er Comple on of Work

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Documen ng Results and Recommenda ons

A er comple ng the service and maintenance work, proper documenta on to record the details
related to the work carried out has to be done. A knowledge bank of all the challenging issues and
rec fica on procedures should be created for future reference. All the documents have to be submi ed
to the seniors at work and any issue related to the service and maintenance work should also be
updated to them.
Records of the following have to be maintained:

Job cards

Work status report

Records of stores and parts

Warranty systems

Records of work carried out

Reports of issues and remedial ac on taken

Reports of tests carried out and their results

Instruc ons/recommenda on to customers like replacement of parts, further

inves ga on and repairs

Customer feedback report

Fig. 4.3.20 Documenta on of Results and Recommenda ons

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Roadside Assistance, Repairs, and Recovery

EVs require special handling with respect to roadside assistance, repairs, and recovery. Manufacturers
of EVs provide informa on regarding the same and is available online for free. The following steps are to
be taken:

Emergency start- Even a er HV ba ery

Roadside repairs- It should be carried
is completely discharged, on some
out only by trained and qualified
vehicles the vehicle can be restarted
people, taking all the necessary
twice for a short distance (for about
precau ons and following repair
100m and 50m respec vely) a er
procedures as done in the workshop.
switching igni on off and on.

Recovery- Along with roadside

assistance numbers, details of how to
details of how to handle the vehicle is
also provided by OEMs to be followed.

Fig. 4.3.21 Procedures for Roadside Assistance

The following are the general steps to be followed during roadside recovery:

Following general precau ons, do not touch any HV component/cable, do not damage
ba ery pack, etc.

Immobilize the vehicle by chocking the wheels and se ng the parking brake.

Deac vate the vehicle by opening the hood, removing access panel, double cut loop to
ensure the ends cannot reconnect.

Con nued...

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Ac vate tow mode, connect tow chain, lower suspension arms, pull out the trailer and
secure the wheels.

Tow the vehicle: with HV system intact, switch-on igni on and select electric freewheel
mode and vehicle can be towed with rope and tow bar/ with damaged HV system,
deac vate freewheel mode and transport vehicle with all wheels sta onary.

Fig. 4.3.22 Procedures for Roadside Recovery

4.3.9 Assist EVSLT in Diagnosis of Faults

A Service Technician who reports to EVSLT should help in inspec ng, diagnosing the fault, and repairing
it. All these procedures have to be carried out as per OEM guidelines and organisa on processes.
Different methods can be used to diagnose faults like customer complaints, test-run of vehicle, using
measuring devices to check various parameters, advice from Supervisors, using diagnos c tools, etc.
Some of the common issues for which inspec on, diagnosis, and repair are required are as follow:
• Vehicle has stopped running
• Vehicle is running slowly
• Short ba ery run me
• Unusual noise from vehicle, etc.
• Problems associated with drive train, steering, brakes, suspension, etc.
• Problems associated with electric box, ba ery pack, motor, LV components, etc.
Steps to follow for diagnosis of faults:

Refer to manual or seek

Perform inspec on Find the fault and its cause
advice for remedial ac on

Carry out remedial ac on if Document the fault and

possible, or else escalate ac on taken for future
the issue reference

Fig. 4.3.23. Steps to follow for Diagnosis of Faults

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Assist EVSLT to check the vehicle performance a er servicing/maintenance/repair work by following

the below steps:
Inspect the vehicle with appropriate devices to check the performance of all the components,
systems and the vehicle.

Conduct a test ride to see the performance of the vehicle.

Compare the test results with the vehicle specifica ons and regulagions.

If there are any discrepancies, seek advice from seniors to rec fy the problem.

Document details of inspec on carried out and remedial ac ons taken.

Fig. 4.3.24 Steps to Check Vehicle Performance

Visual Inspec on of EV for Diagnosis of Faults

The following steps have to be taken to carry out visual inspec on of EV:
1. Carriage check:
• Vehicle iden ty (Chassis number, number plate, etc.)
• Body work (any damages, dents, etc.)
• Lights and indicators
• Accessories (Horn, wind screen, power windows, air-bags, etc.)
• Steering wheel
• Wheels and types
2. Under carriage check (The vehicle has to be placed over an inspec on pit):
• Chassis
• Suspension system
• Steering system
• Brake system
• Fluid leakage
• High voltage cables and wiring
3. Wheel alignment check:
• Check front wheel movement as per OEM technical specifica ons
4. Brake test:
• Check the performance of brakes using a brake tester

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5. Headlight alignment test:

• Check for the alignment of headlights and func oning of indicators as per OEM technical
specifica ons
• Check the luminous intensity of the headlights and indicator
6. Drive motor sound test:
• Check the sound emi ed by the drive motor
7. So ware check:
• Check for components like sensors, electronic components, GPS, etc. which are regulated by
the so ware as per OEM guidelines
The following checklist can be used while carrying out inspec on of vehicles:

Fig. 4.3.25 EV Inspec on Checklist

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Types of Faults in EV
The various faults in an EV can be categorised as mechanical, electrical, and so ware faults.
Mechanical Faults
These are faults associated with suspension system, steering, tyres, brakes, fluid levels, etc.

Faults in tyres include worn out tyres, tyre bulges and cracks, over or under inflated tyres, misaligned
tyres, slow punctures, etc.

Following general precau ons, do not touch any HV component/cable, do not damage ba ery pack,
etc.

Faults in steering include vibra ons while driving, s ff steering, misaligned steering, steering not
returning to centre a er turning, noisy steering, etc.

Faults in brake include worn out brake shoes or pads, brake fluid leakage, noisy braking, vibra ons
while braking, vehicle pulling to one side while braking, so brakes, burning smell, etc.

Fault in fluids like coolant, brake and wiper fluid include fluid levels going below normal level and
contamina on.

Fig. 4.3.26 Mechanical faults

Electrical Faults
These are faults associated mainly with ba ery, motor, inverters, and converters.

Faults in ba ery include over-charge, over-discahrge, over-hea ng, short circuit of inter cell,
inaccurate es ma on, etc.

Faults in motor include issues in stator winding, bearing failure, broken rotor bar, eccentricity related
faults, etc.

Faults in inverters and converters

Fig. 4.3.27 Electrical faults

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Warning Light Descrip on

Charging indicator: This feature provides HV ba ery charging

status.

Zero Charge/ Low Charge: This feature provides High Voltage

ba ery status.

Ba ery High Temperature Tell-tale: This feature provides HV

ba ery high temperature status.

Motor High Temperature Tell-tale: This feature provides

trac on motor high temperature status.

Limp Home Mode Tell-tale: This feature provides vehicle

limp home mode indica on. This tell-tale turns ON to
indicate that the EV system with limited performance mode
is ge ng ac vated to cau on user to charge the EV.

Blinking: HV Cri cal Fault.

Con nuously ON: HV Cri cal Fault Mobility is not allowed

State Of Charge (SoC): Gauge for High Voltage Ba ery

Table 4.3.28 Warning Lights for EVs (Source: www.nexonev.tatamotors.com)

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Test Ride A er Comple on of Work

The following steps have to be taken for carrying out a road test following a service/
maintenance/repair:

Refer to OEM manual

Check the starter and inhibitor switch

Check all the warning indicators

Check the brakes

Check engine and motor noise, vibra on, performance, etc.

Check steering for effort required, noise, free play, etc.

Check suspension system for irregulari es in ride, noise, etc.

Check the wheels and tyres

Check horn, lights, indicators, etc.

Table 4.3.29 Steps to Carryout Test Ride A er Comple on of Work

If any problems are no ced a er test ride, rec fy them. Compare the test results with the vehicle
specifica ons. If there are any discrepancies, seek advice from seniors to rec fy the problem. Document
the details of inspec on carried out and remedial ac ons taken.

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Summary
• The professional code of ethics outlines the principles that govern the organiza on behaviour and
decisions. They provide outline of how the workers should behave, give guidance related to
handling issues like safety, harassment, abuse, and conflict of interests.
• It is important to follow health and safety measures at the workplace to protect men, materials, and
machines. Every organisa on has to be compliant with health and safety guidelines provided by the
State and legal authori es.
• Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security
have to be followed. The job card has to be obtained and the work that needs to be done has to be
analysed and understood. All the technical data required should be obtained from OEM manuals
and from the Lead Technician.
• These are documented processes that an organisa on has to ensure that work, service, and quality
are maintained and delivered consistently. SOPs help in preven ng risks, reducing errors,
minimizing rework and achieving greater efficiency.
• Electric vehicles comprise of high-voltage components and other aggregates that require safe
handling to prevent injuries, death or damage to equipment and the workplace. It is important to
make note of all the safety measures outlined by the manufacturers.
• Electrical work should be started only a er taking all precau onary measures against short-circuits,
electric shock, and arcs. No work should be performed on live parts of electrical systems and
equipment. All high voltage electrical systems should be handled only by trained personnel wearing
proper PPE and by all the precau onary measures. Generally, in EV workshops low voltage means
12V -24V and high voltage means over 60V.
• While dealing with high voltage components, safety against Electrosta c Discharge (ESD), High
Voltage (HV), and Ba ery Charging Equipment has to be taken.
• It is always advisable to keep all HV items in an enclosed and insulated loca on. The devices
available to protect against high voltages and excess current flow are fuses, miniature circuit
breakers (MCBs), residual current devices (RCDs) and residual current breaker with over currents
(RCBOs).
• The various electrical/electronic components are ba ery, motor, relays (switching components),
control units, on-board charger, charging points, isolators (safety devices), inverter (DC to DC
converter), ba ery management system (BMS), igni on or key-on control switch, and display panel.
• All ma er is made up of ny par cles called atom. An atom consists of a central nucleus made up of
protons and neutrons and around the nucleus, the electrons orbi ng the nucleus.
• Components in electrical circuits are conductors, insulators, semi-conductors, resistors, capacitors,
inductors, transistors, and integrated circuits.
• When an electromo ve force or voltage is applied to a conductor, a direc onal movement of
electrons will take place. For example: when a ba ery is connected to a wire, then the source will be
the ba ery and the wire is the conduc ng path in which the electrons move. An electron flow is
called electric current.
• Effects of current flow in a circuit are hea ng, magne c, and chemical.
• In a Series circuit all components are connected end to end forming a single path for the current
flow.

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• In a Parallel circuit all components are connected across each other forming mul ple paths for the
current flow.
• Magne sm can be created by a permanent magnet or by an electromagnet. Magne c field is the
space around a magnet in which a magne c field can be detected.
• When a conductor is cut by magne sm, a voltage is induced in the conductor.
• The direc on of the induced voltage depends on the direc on of the magne c field and the
direc on in which the field moves rela ve to the conductor.
• The voltage level is propor onal to the rate at which the conductor is cut by the magne sm.
• Electromagne c induc on is the basis on which a generator works. Generator is a machine that
converts mechanical energy into electrical energy.
• If two coils known as primary and secondary coils are wound onto a same iron core, then any change
in magne sm of one coil will induce a voltage in the other. This can be achieved by switching on and
off the current to the primary coil.
• DC-DC converter works on the mutual induc on principle.
• There are various symbols, units, and terms used in the wiring diagrams of electrical and electronic
circuits. These are universal conven ons used across all industries worldwide.
• Electrical input refers to the amount of energy put into a device and electrical output refers to the
amount of energy that comes out of a device.
• Pulse width modula on is a method used to reduce the average power delivered by an electrical
signal, by effec vely chopping it up into discrete parts.
• Analog signals are con nuous in both values and me and are bound within a certain range.
• Digital signals represent data as a sequence of discrete values.
• Fiber-op c communica on is a way of transmi ng informa on from one place to another by
sending pulses of infrared light through an op cal fibre.
• An Electric Vehicle is composed of many parts/components and subsystems such as body design,
energy source, electric pulsion, and auxiliaries. It consists of mechanical and electrical components.
• The various mechanical components are drivetrain, brake, suspension, steering, chassis, body,
wheels, and tyres.
• EV service process involves the steps to be followed from the me of service booking to ge ng
feedback from customers to follow-up a er EV servicing.
• The first source of informa on related to the work to be carried out can be obtained from the job
card. Job cards are used in workshops to send job details to service technicians and get informa on
back on the work.
• Electric Vehicles require maintenance far lesser and more frequent maintenance than ICE vehicles.
Preven ve maintenance of EVs helps in avoiding breakdowns and costly repairs and ensures safety.
Some of the recommended maintenance/servicing steps by OEMs include inspec on of tyres wear
and tear, checking tyre pressure, inspec on and replacement of filters, wheel alignment,
windscreen wiper replacement, brake-fluid change, etc.

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• Visual inspec on is carried out to see if there are any damages or defects in the vehicle.
• The various faults in an EV can be categorised as mechanical, electrical, and so ware faults.
• Whenever any kind of maintenance or repair work is carried out, if proper care is not taken, then
work on one system may affect another system. Especially when work is being carried out on HV
components, connec ons to other systems have to be considered.
• The various tools and equipment used in the maintenance, servicing, and repairing of EVs can be
broadly classified as tools, tes ng equipment, and workshop equipment.
• It is important to ensure that no HV ac vity is conducted around the area of the worksta on
because, even a er isola on, HV components like ba eries, motors, and other components may
s ll contain large amounts of high voltage and energy.
• An EV is composed of non-HV components like mechanical and low-voltage electrical components.
• All HV maintenance and replacement work should be carried out by following all the safety
procedures and OEM guidelines.
• A er comple on of work-appropriate steps have to be taken to re-energize the system.
• Service Technician who reports to EVSLT should help in inspec ng, diagnosing the fault, and
repairing. All these procedures have to be carried out as per OEM guidelines and organisa on
processes.
• A er the comple on of the assigned work, all the work carried out has to be documented for future
reference

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Exercise
Answer the following ques ons:
1. What are the precau ons to be taken while working on HV components of an EV?
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
2. List all the mechanical and electrical aggregates in an EV.
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

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5. Perform rou ne
service and repairs
of a four wheeler
EV
Unit5.1 - Basics of a Four-Wheeler EV
Unit5.2 - Rou ne Service and Repairs of a Four-Wheeler
EV

ASC/N1450
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Key Learning Objec ves

At the end of this module, the trainee will be able to:
1. Demonstrate preparatory ac vi es for diagnosing faults and repairing of a four wheeler EV
2. Demonstrate how to use different techniques for diagnosing faults and repairing the four wheeler
vehicle

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Unit 5.1 - Basics of a Four-Wheeler EV

Unit Objec ve
At the end of the unit, the trainee will be able to:
1. List various components /aggregates and the manufacturer's specifica ons of a four wheeler EV
2. Discuss basic technology used, func oning and interconnec ons of various systems and
components of a four wheeler EV

5.1.1 Components in Electric and Hybrid Four-Wheeler

Vehicle
Conven onal vehicles which run on petrol/diesel use an Internal Combus on Engine (ICE), whereas EVs
use electrical energy stored inside a high voltage ba ery for propulsion of the vehicle. Hybrid vehicles
have addi onal mechanical parts as it uses ICE.
The main mechanical components in Electric and Hybrid Four-Wheeler Vehicles are:

Name of Mechanical Component Image

Chassis and Body

Source: www.favpng.com

Drive train

Source: www.analog.com

Con nued...

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Name of Mechanical Component Image

Brake system

Source: www.trive ebodyrepair.com

Suspension system

Source: www.whichcar.com.au

Steering system

Source: www.carthro le.com

Con nued...

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Name of Mechanical Component Image

Wheels and tyres

Source: www. rereview.com

Internal combus on engine

Source: www.autonews.com

Fuel supply system

Source: www.newkidscar.com

Exhaust system

Source: www.researchgate.net

Con nued...

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Name of Mechanical Component Image

Cooling system

Source: www.trade.mechanic.com.au

Table 5.1.1 Mechanical Components in Electric and Hybrid Four-Wheeler Vehicles

The main electrical components in Electric and Hybrid Four-Wheeler Vehicles are:

Name of the electrical component Image

On-board charger (OBC)

Source: www.electraev.com

Inverter

Source: www.emobility-engineering.com

Con nued...

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Name of the electrical component Image

DC-DC convertor

Source: www.indiamart.com

Electric motor and IC engine (hybrid

vehicles)

Source: www.engineering.com

High-voltage ba ery

Source: www.allaboutcircuits.com

Con nued...

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Name of the electrical component Image

Power distribu on unit

Source: www.chargedevs.com

Table 5.1.2 Electrical Components in Electric and Hybrid Four-Wheeler Vehicles

5.1.2 Basic Technology of Electric Four-Wheeler Vehicles

An Electric Vehicle consists of four major subsystems, body design, energy source, propulsion system
and auxiliaries. The main working mechanism of the vehicle is based on the energy source and the
propulsion system.

Notes

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5.1.2.1 Basic Technology of Pure Electric Four-Wheeler

Vehicle

Fig. 5.1.1 Pure Electric Four-Wheeler Vehicle

(Source: www.afdc.energy.gov)

A pure electric Four-Wheeler is powered by a ba ery and does not use fuels like petrol and diesel. These
are known as Pure Electric Vehicles (PEV) or Ba ery Electric Vehicles (BEV). These vehicles do not use
fuel hence, they are zero emission vehicles. Most of the electric cars have two types of ba ery systems, a
high-voltage ba ery which powers the inverter and the electric motor which in turn propels the vehicle
and a low-voltage ba ery (12V) which provides power to the lights, audio system, wind-screen wipers,
etc. The voltage ba ery has to be charged with electricity before driving the vehicle. As the vehicle is
driven, the ba ery loses its charge (discharges) and when it completely gets discharged, the vehicle
needs to be plugged-in for charging again. Most vehicles also have regenera ve braking i.e., when the
vehicle is decelera ng or braking, the motor works as a generator and converts the kine c energy to
electrical energy to charge the high-voltage ba ery

Fig. 5.1.2 Block Diagram of Pure Electric Four-Wheeler Vehicle Subsystems

(Source: h ps://www.sciencedirect.com/science/ar cle/pii/S2095756420300647)

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5.1.2.2 Basic Technology of Hybrid Four-Wheeler Vehicle

Fig. 5.1.3 Hybrid Four-Wheeler Vehicle

(Source: www.afdc.energy.gov)

These vehicles are also known as HEVs. They use both electrical power and ICE to propel the vehicle. It
uses the electric propulsion system when the power demand is low, for example, when a vehicle is
moving at a slow speed. It also reduces the fuel consump on as the engine stays off during idle periods,
therefore, reducing emissions. When the vehicle is moving at higher speeds, HEV switches to ICE. The
ICE can charge-up ba eries and they can also retrieve energy by means of regenera ve braking like in
PEVs. HEVs are primarily ICE powered cars which use an electrical drive train to improve mileage or for
be er performance. HEVs cannot be charged from electricity grid. The ICE and electrical propulsion
systemin a HEV can be connected in a series format, parallel format or series-parallel format as shown
below:

Fig. 5.1.4 Block Diagram of Series Hybrid Four-Wheeler Vehicle Subsystems

(Source: h ps://www.mdpi.com )

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Fig. 5.1.5 Block Diagram of Parallel Hybrid Four-Wheeler Vehicle Subsystems

(Source: www.mdpi.com)

Fig. 5.1.6 Block Diagram of Series-Parallel Hybrid Four-Wheeler Vehicle Subsystems

(Source: www.mdpi.com)

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5.1.2.3 Basic Technology of Plug-in Hybrid Four-Wheeler

Vehicle

Fig. 5.1.7 Plug-in Hybrid Four-Wheeler Vehicle

(Source: www.afdc.energy.gov)

These vehicles are also known as PHEVs. They also use both electrical power and ICE to propel the
vehicle like HEVs, but the difference between them is that PHEVs use electrical power as the main
driving force. Therefore, they require higher capacity ba eries than HEVs. PHEVs start in an all-electric
mode and runs on electricity and when the ba eries get low on charge/ discharged, it switches to ICE to
provide the power or to charge-up the ba ery. PHEVs can be directly charged from the grid.

Fig. 5.1.8 Block Diagram of Plug-in Hybrid Four-Wheeler Vehicle Subsystems

(Source: www.researchgate.net)

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5.1.2.4 Basic Technology of Fuel Cell Electric Four-Wheeler

Vehicle

Fig. 5.1.9 Plug-in Hybrid Four-Wheeler Vehicle

(Source: www.afdc.energy.gov)

These vehicles are also known as FCEVs. They have hydrogen fuel cells that use chemical reac ons to
produce electricity which in turn propels the vehicle. For the chemical reac on to take place, hydrogen
and oxygen are required. Hydrogen is supplied from special high-pressure tanks that are installed in the
vehicle and oxygen is obtained from air sucked in from the surroundings. Excess energy is stored in the
ba eries. FCEVs produce water as a byproduct which is let out of the vehicle from tailpipes.

Fig. 5.1.10 Block Diagram of Fuel Cell Electric Four-Wheeler Vehicle Subsystems
(Source: www.seman cscholar.org)

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Unit 5.2 - Rou ne Service and Repairs of a Four-Wheeler EV

Unit Objec ve
At the end of the unit, the trainee will be able to:
1. List the types of tools and equipment used in different processes of a four wheeler EV maintenance
2. List the ac vi es need to perform for preparing a four wheeler EV for fault iden fica on and
repairing work
3. Discuss the symptoms of technical faults, their causes and rec fica on procedures in a four wheeler
EV
4. Explain the health and safety measures and regula ons w.r.t. equipment and components during
fault diagnosis

5.2.1 Prepare to Perform Rou ne Service and Repairs on a

Four-Wheeler EV
Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security has
to be followed. The job card has to be obtained and the work that needs to be done has to be analysed
and understood. All the technical data required should be obtained from OEM manuals and from the
Lead Technician. It is a legal requirement for EV workshops to protect its people and workplace from
poten al risks especially while dealing with High-Voltage components. This can be achieved by carrying
out risk assessment, training of workers in safe work prac ces and maintain safe work environment.

5.2.1.1 Guidelines for Service/Repair of Four-Wheeler EVs

Only trained personnel should carry work on Evs.

Always wear appropriate PPE for the work being carried out.

Do not wear loose clothing and jewelry while servicing/repairing vehicles.

Always use recommended tools and equipment.

Always follow OEMs instruc ons during servicing, maintaining and repairing of the vehicle.

Con nued...

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Carry out work only in an authorized and well-ven lated area.

Remove keys from the key switch and remove the ba ery wire before any work.

Deenergize the system as per OEM instruc ons.

Always use correct ways of handling HV components.

Always use insulated tools while working on electrical components.

Always check the polarity of the ba ery terminal and rewire correctly.

Always use OEM approved spare parts while replacing parts.

Li , hoist and secure the vehicle as per the OEMs recommenda on.

Always block chassis before working underneath it.

Always carry out maintenance work away from sources of exposed flame.

Replace missing or damaged warning, informa on or cau on labels.

Be aware of the common risks in workshops and steps to prevent them.

Be aware or emergency response techniques.

Follow appropriate guidelines and environmental regula ons in handling, storage and disposal of
hazardous chemicals and materials.

Be aware the procedures to record and report faults that cannot be rec fied by self.

Always maintain documents of all the work carried out on the vehicle.

Fig. 5.2.1 Guidelines for Service/Repair Four-Wheeler EVs

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5.2.1.2 Tools and Equipment

The various tools and equipment used in maintenance, servicing and repairing of EVs can be broadly
classified as tools, tes ng equipment and workshop equipment.

Tools Image
Spanner is used to provide grip while
applying torque to objects like nuts
and bolts. The most common type of
spanners are open and ring spanners.

Socket wrench is a type of spanner

that has a closed socket format.

Screw drivers are used to removing

and installing screws. They can be
manually operated or power
operated.

Pliers and Wire cu ers are used to

grip small objects, hold wires, bend
wires and loops and a ach wires.
They can also be used to cut wires
with minimal damage to the
insula on or internal conductors.

Con nued...

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Tools Image
Auto-trimming tools are used to
remove door panels, dashboards,
fasteners, etc. They can also be used
from trimming, molding and scarping.

Source: www.ubuy.com
Hex or Allen key wrenches are used to
drive bolts and screws with a
hexagonal socket.

h ps://www.freepik.com/premium-photo/hex-key-set
Tyre spoon levers are used to separate
tyres from the wheels.

Source: www.amazon.com
Adjustable locking spanner wrenches
are used to grip fasteners like nuts and
bolts of all sizes.

Source: www.amazon.com

Con nued...

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 Electric Vehicle Service Technician

Tools Image
Torque wrenches are used to apply a
specific torque to nuts and bolts.

h ps://www.freepik.com/premium-photo/set-new-heads-
with-ratchet-wrenches-car-repairs
Impact wrenches are used to deliver
high torque output with minimal
exer on by the user. They are used
along with impact sockets.

Hammers are used in many different

applica ons in auto-repair work.
There are different types of hammers
used for carrying out various repair
works.

Source: www.istockphoto.com
Pullers

Ball joint separators are used to

remove ball joints from the steering
knuckle.

Source: www.aliexpress.com

Con nued...

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Par cipant Handbook

Tools Image
Bearing pullers are used to remove
components like gears, pulleys,
bearing, etc. from sha s.

Pressure gauges

Fuel pressure gauges are used to

measure and indicate the quan ty of
fuel in the fuel tank. It helps to ensure
that there is enough fuel available for
combus on.

Manifold gauges are also known as

HVAC gauges and are used to
diagnose and repair cooling systems
in vehicles.

Oil pressure gauges are used to check

oil pressure in the main oil pipes near
the pump and filter.

Tyre pressure gauges are used to

measure the pressure in inflated tyres
in the wheels of vehicles.

Con nued...

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 Electric Vehicle Service Technician

Tools Image
Measuring equipment

Vernier calipers are used to measure

the inner and outer dimensions of
objects.

Micrometers are used to measure

thickness, diameter and length of
solid objects.

Feeler gauges are used measure the

gap between two parts.

Mul meters are also known as

Volt/Ohm meter or VOM, they are
used to measure voltage, resistance
and current

Flowmeters are used to measure the

volume or mass of gases and liquids.

Con nued...

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Par cipant Handbook

Tools Image
Temperature gauges are used to
m o n i to r t h e te m p e rat u re a n d
temperature gradient of an item
being monitored.

Dial gauges are used to measure

minute lengths and displacement
accurately.

Ba ery hydrometers are used to

measure the specific gravity (density)
of the ba ery's electrolyte, which
helps in determining the state of
charge of the ba ery.

Source: www.indiamart.com
Ba ery maintenance kits contain
insulated tools and other devices
required for ba ery maintenance.

Source: www.matcotools.com

Con nued...

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 Electric Vehicle Service Technician

Tools Image
Workshop equipment

Electric drills or power drills are used

to make a hole in a variety of materials
and also to drive screws through
different materials.

Welding machines are used to

permanently join metal pieces and
objects with the help of heat. Electric
and gas welding machines are two
types of welding machines available.

Source: www.indiamart.com
Cranes are used to li and lower or
move material and objects
horizontally with help of hoist chains
and cables.

Source: www.eurocarparts.com
Ramps and hoists are used to li
vehicles so that repair and
maintenance works on the
undercarriage of vehicles can be
carried out.

Source: www.eurocarparts.com

Con nued...

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Par cipant Handbook

Tools Image
Jack and axle stand is used to support
the weight of vehicles and hold it in
place while replacing tyres and other
parts under the vehicle.

Wheel chocks are used to prevent the

move movement of wheels while
servicing the vehicle.

Source: www.indiamart.com

Table 5.2.1 Tools, Measuring Devices and Workshop Equipment

Notes

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 Electric Vehicle Service Technician

5.2.1.3 Specifica ons of the Vehicle

It is important to know the specifica ons of the vehicle before taking up any work on the vehicle. This
will help to check if all the parameters are as specified and makes fault finding easier. Apart from
diagnosis, it will also help to cross-check the parameters a er servicing.

Note: Refer to the OEM manual for the specifica ons related to a par cular Model of the vehicle.

Electric and Hybrid Four-wheeler Vehicle Specifica ons:

• Sedan, SUV, XuV, etc.

• Length x Width x Height
Body type and
• Wheelbase
dimensions
• Ground clearance
• Boot space

• Motor type
• Controller type and rated voltage
• Rated voltage
Motor
• Rated power
• Maximum motor power
• Maximum motor torque

• Ba ery type, rated voltage and capacity

Ba ery and • Charging standard and specifica ons

charging system • Portable charging cable
• Charger op ons

Suspension
• Front and back shock absorbers
system

• Type of steering and turning radius

Steering system • Steering wheel
• Steering column

• Specifica ons of front wheel and tyres

• Air pressure of front tyres
Wheel and tyre
• Specifica on of rear wheel and tyres
• Air pressure of rear tyres

Con nued...

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• Hand brake
• Pedal brake
Braking system
• Type of front and rear brake discs
• Type of front and rear brake pads

• Ba ery cooling system

• Trac on cooling system
• Transaxle oil
Lubricant
• Brake fluid
• AC compressor oil
• Refrigerant

• Head light
• Rear tail lamp/lamps
• Turning signal lights
Ligh ng and
• Brake light
display
• Display
• USB charging interface
• Central control unit

Fuel • Fuel type and fuel tank capacity

• Engine type
• Engine displacement

Engine and • No. of cylinders/No. of valves per cylinder

transmission • Max. power
• Max. torque
• Type of transmission

Fig. 5.2.2 Electric and Hybrid Four-Wheeler Vehicle Specifica ons

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Types of Electric Vehicles

Generally, there are three main types of electric vehicles:
1. Ba ery Electric Vehicle (BEV)
A Ba ery Electric Vehicle (BEV) is a full electric vehicle. Other than motors and ba eries, this type of
electric vehicle has no other sources of actua on. These vehicles emit zero emissions. An external
power source, such as a DC quick charger or an AC charger, is used to recharge the ba ery. The BEVs
typically require 8 hours to completely charge using an AC charger. Using a DC fast charger will reduce
this me to one hour. Depending on the ba ery size and the motor, these electric vehicles can travel 250
to 500 kilometers. Some examples of BEVs in India are TATA Nexon, TATA Tigor, TATA Tiago, MG ZS,
Mahindra XUV300, Hyundai Kona.

Fig. 5.2.3 BHEV Architecture

(Source: h ps://e-amrit.ni .gov.in/types-of-electric-vehicles)

Fig. 5.2.4 TATA Nexon EV

(Source: h ps://www.carwale.com/tata-cars/nexon-ev/)

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TATA NEXON EV Specifica ons

Specifica on Value

Motor Type Permanent magnet synchronous AC motor

Electric Motor Power (PS) 143

Electric Motor Torque (Nm) 250

Ba ery Pack 40.5 kWh high energy density Lithium-ion ba ery pack

Thermal Management System Liquid Cooled

Charging Standard CCS 2

Charger Op ons 3.3 kW wall box charger or 7.2 kW AC fast charger

Es mated regular charging me (SOC 10% 15 hours

to 100% from any 15 A plug point)

Es mated regular charging me (SOC 0% to 6.5 hours

100% from 7.2 kW AC fast charger)

Es mated fast charging me (SOC 0%-80%) 56 minutes

from 50 kW DC fast charger

Drive Range 437 kms

Table 5.2.2 Nexon EV Specifica ons

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2. Hybrid Electric Vehicle (HEV)

Hybrid Electric Vehicles are powered by both IC engine and electric motor in order to provide more fuel
efficiency. The vehicle's own braking system produces the electricity. The brakes' heat is transformed
into electrical energy. This process is called as regenera ve braking. A hybrid electric vehicle not
required to plug in to charge. Instead, the ba ery is charged by the internal combus on engine and
through regenera ve braking. Some examples of HEVs in India are Toyota Hyryder, Toyota Camry, Maru
Grand Vitara, MG Hector, Honda Civic.

Fig. 5.2.5 HEV Architecture

(Source: h ps://e-amrit.ni .gov.in/types-of-electric-vehicles)

Fig. 5.2.6 Maru Grand Vitara Hybrid

(Source: h ps://www.carwale.com/maru -suzuki-cars/grand-vitara/)

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Grand Vitara Hybrid Specifica ons

Specifica on Value

Ba ery Type Lithium-ion

Ba ery Voltage 177.6 V

Maximum Power 59 kW @ 3995 rpm

Maximum Torque 141 Nm @ 0-3995 rpm

Motor Generator Type AC Synchronous Motor

Transmission Type e-CVT

Table 5.2.3 Grand Vitara Hybrid Specifica ons

3. Plug-in Hybrid Electric Vehicle (PHEV)

Plug-in Hybrid Vehicles generally recharge the ba eries through an external power or regenera ve
braking. The PHEV ba ery pack is bigger than a standard hybrid electric vehicle. Some examples of
PHEVs in India are Volvo XC90, Porsche Cayenne.

Fig. 5.2.7 PHEV Architecture

(Source: h ps://e-amrit.ni .gov.in/types-of-electric-vehicles)a

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Fig. 5.2.8 Volvo XC90 PHEV

(Source: h ps://www.carwale.com/volvo-cars/xc90/)

Volvo XC90 Specifica ons

Specifica on Value

Motor Type Dual Permanent Magnet Synchronous Motors

Maximum Motor Power 87hp @ 7000 rpm

Maximum Motor Torque 240Nm @ 0-3000 rpm

Ba ery Capacity 9.2 kWh

Charging Time 6 hrs.

Table 5.2.4 Volvo XC90 PHEV Specifica ons

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5.2.2 Visual Inspec on of Four-Wheeler EVs

Steps to park the vehicle before carrying out inspec on:
• Park the vehicle on level ground
• Shi to parking posi on
• Apply parking brake
• Put the power bu on in OFF posi on
• Block both front and rear tyres with chocks
Pre-service visual inspec on helps the service team to assess the problems/faults in the vehicle in
addi on to customer complaints. This also helps to organize for the tools, spare parts and other
equipment that are likely to be required. The vehicle has to be set on a flat ground before inspec on.
Inspec on of the following parts of the vehicle has to be carried out:

Part Inspec on item Inspec on observa on

Appearance Outer parts

Screws, fasteners, nuts and

bolts

Front and rear shock

absorbers

Damages, deforma ons,

corrosion, open wire
insula on, loose wire
connec ons, sharp edges, etc.

Fixed assembling Hood, bumpers, fenders,

doors, trunk, windows, etc.

Steering

Front and rear tyres

Front and rear wheels and

wheel-hub assembly

Front and rear axles

Airbags, door components,

accelerator pedals, windshield
wipers, etc.

Con nued...

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Part Inspec on item Inspec on observa on

Braking system Appearance

Assembly clearance

Abnormal brake noise

Brake fluid volume

Response me

Braking distance

Electronic components Ligh ng

Power lock

Display panel

Vehicle insula on

Alarm and horn

EBS energy recovery

Controller

Wheel and tyres Defla on, air-leakage or

puncture in tyres

Torque wheel nuts

Wear and tear of tyres

Tyres tread depth

Ba ery Coolant level

Charger modules

Cables and connec ons

Con nued...

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Part Inspec on item Inspec on observa on

Engines Abnormal noises

Oil leakage, oil level and

condi on

Exhaust smoke at idle speed

and mid-engine speed

Crankcase ven la on system-

hoses, orifice, control valve
and air cleaner condi on

Radiator and fan motor shroud Corrosion

(FMS)
Dust and par cle build-up and
clogging
Coolant level

So ware Display so ware version

ECU so ware version

FOC so ware version

BMS se ng

Table 5.2.5 Checklist for Visual Inspec on Four-Wheeler EVs

Notes

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5.2.3 Iden fica on of faults/troubleshoo ng

The faults in a vehicle can be diagnosed either using the DTC (Diagnosis Trouble Code) or manually
based on the symptoms. In the DTC process, the malfunc oning part is iden fied using a process of
elimina on and the possible trouble area are eliminated one a er the other using the so ware and
inspec on of related parts. The following flowchart shows the process to iden fy faults:

Check ba ery voltage, if

Ask customer for specific
Receive vehicle in voltage is less, then
problems and how it
Workshop. recharge or replace the
occured.
before proceeding.

Check fuses, cables and

If DTC output is shown, then
connectors. Warm up If there is no DTC output,
look for the trouble area in
engine to normal opera ng then look for the problem
the DTC chart for poten ally
temperature. Confirm symptoms in the table or
malfunc oning parts and
problem symptoms and seek seniors advice.
circuit.
check for DTC.

Inspect and iden fy the Adjust, repair or replace the Carry out confirma on test
malfunc oning the part or malfunctuioning part or to ensure that the
circuit. circuit. malfunc on does not recur.

Fig. 5.2.9 Flowchart for Iden fica on of Faults

Notes

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5.2.3.1 Steps to follow while using DTC check method

In the DTC check it is important to know if the problem s ll occurs or has occurred in the past and
returned to normal. The DTC should be compared with the problem symptom to check if they are
related. DTC should be checked before and a er confirma on of symptoms to see whether the problem
symptoms exists or not and to determine the current system condi ons.

Make a note of the DTC

Check DTC. displayed and clear Confirm the symptoms.
memory.

If there is no DTC output,

then troubleshoot for each
If there are no symptoms, possible symptom. The
then carry out simula on If there are symptoms, carry problem s ll occurs in a
test using symptom out DTC check again. place other than circuit. DTC
simula on methods. displayed first may be a
past primary problem or a
secondary problem.

If symptoms exist and was

displayed in the ini al DTC
check, then the problem
may be in the cable or
connector in the circuit in
the past. Check cable and
connector.

Fig. 5.2.10 Steps for DTC Check method

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5.2.3.2 Symptom simula on test to find faults

It is most difficult to troubleshoot when no problem symptom occurs, which requires a thorough
problem analysis. A simula on in similar condi ons and environment in which the problem occurred in
the vehicle should be carried out. For example: A problem can arise while the vehicle is being driven in
extreme hot or cold weather condi ons or when the road is very uneven leading to vibra ons, etc.
These problems may not occur when the vehicle is in a sta onary condi on or in workshop
environment.
In such situa ons a simula on test can be carried out. For the symptom simula on test, the problem
symptoms and the problem areas/ parts have to be confirmed. Then the tester has to be connected to
the par cular circuit or part and carry out the symptom simula on test, judging if the circuit or part
being tested is normal or defec ve. Confirm the problem symptoms and refer to the problem symptoms
manual for each system to deduce the possible causes.
To simulate vibra ons, the part or circuit can be slightly tapped with a finger or slightly shaking the
cables and connectors, ensuring that there is no damage or loosening of the connec ons. To simulate
heat, a device like hair dryer can be used ensuring that the temperature is below 60 degree C and no
direct heat is applied. For simulate wet condi ons, water can be sprinkled in front of the radiator and
not directly on the circuits or parts. To simulate high electrical load, switch on the headlights, defogger,
heaters, blowers and other electrical loads and check if malfunc on occurs.
DTC chart:
A DTC chart consists of the following informa on:

Item Descrip on

DTC display Indicates the diagnos c trouble code.

Detec on system Indicates the details of the problem or the system.

Trouble area Indicates the suspected areas of the problem.

Page details Indicates the page number where details of inspec on, repair and replacement
are given for the problem.

Table 5.2.6 Informa on in a DTC Chart

Problem symptoms chart:

DTC may not detect and show a problem in some cases either because it is beyond the detec on range
or in a completely different system. In such situa ons, the problem symptoms table can be referred to.
A problem symptoms chart consists of the following informa on:

Item Descrip on

Symptom The descrip on of a par cular problem.

Suspected area Indicates the part or circuit that needs to be inspected.

Page details Indicates the page number where details of inspec on, repair and replacement
are given for the problem.

Table 5.2.7 Informa on in a Problem Symptoms Chart

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The table below show some of the warning lights and their descrip on seen in Four-wheeler Evs:

Warning Light Descrip on

Charging indicator: This feature provides HV ba ery charging

status.

Zero Charge/ Low Charge: This feature provides High Voltage

ba ery status.

Park Brake / Brake Fluid low/ EBD malfunc on: This feature
indicates:
• Low level of brake fluid
• Parking brake is applied
• Fault in Electronic Brake force Distribu on (EBD) system

Ba ery High Temperature Telltale: This feature provides HV

ba ery high temperature status.

Motor High Temperature Telltale: This feature provides

trac on motor high temperature status.

Limp Home Mode Telltale: This feature provides vehicle limp

home mode indica on. This telltale turns ON to indicate that
the EV system with limited performance mode is ge ng
ac vated to cau on user to charge the EV.

Blinking: HV Cri cal Fault.

Con nuously ON: HV Cri cal Fault Mobility is not allowed

State Of Charge (SoC): Gauge for High Voltage Ba ery

Table 5.2.8 Warning Lights in Four-Wheeler EVs (Source: www.nexonev.tatamotors.com)

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5.2.4 Perform Rou ne Service and Repairs on a

Four-Wheeler EV
Steps to li the vehicle with floor jack before carrying out servicing and repair work:

Engage the parking brake before jacking up the vehicle.

Check if the floor jack is rated at a capacity higher than the vehicle weight.

Li the vehicle sufficiently from the floor to allow the placement of jacks.

To li the front, engage parking brake, place wheels chocks behind the rear wheels
and place the jack stands under the frame on the right and le sides.

To li the rear, place wheels chocks in front of the front wheels and place the jack stands
under the frame on the right and le sides.

A er the comple on of work, li the vehicle, remove the jack stands and lower the vehicle to
the floor.

Fig. 5.2.11 Steps to Li Vehicle with Floor Jack

5.2.4.1 Carry out On-Vehicle Inspec on

The Motor Compartment of Electric Four-Wheeler Vehicle typically consists of:
• High voltage components
• Coolant reservoir
• Low-voltage ba ery
• Fuse box
• Brake fluid reservoir
• Windshield washer fluid reservoir

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Fig. 5.2.12 Motor Compartment of Four-Wheeler EVs (Source: www.nexonev.tatamotors.com)

Steps to carry out on-vehicle inspec on in a Four-Wheeler EV:

• Turn the wheel to make sure that it can be rotated smoothly without
any abnormal noise.
• Check wheel alignment.
Inspec on of • Check for loose wheel lug nuts.
Wheels
• Check tyre pressure with pressure gauge.
and Tyres
• Check tyres for cuts, damages or embedded sharp objects.
• Check tread depth.
• Check flatness of front and rear wheels.

Inspec on of • Check for smooth opera on of accelerator pedal.

Accelerator pedal • Check for uneven resistance or s ck in certain posi ons.

Con nued...

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• Check brake line pipes and hoses for damage, wear, deforma on,
cracks, corrosion, leaks, bends and twists.
• Check all clamps for ghtness.
• Check for smooth opera on of brake pedal.
Inspec on of
• Check parking brake shoe clearance, parking brake pedal travel and
Brake system
parking brake cables.
• Check front and rear brake pads and discs.
• Check brake fluid.
• Check handbrake and its se ngs.

• Check front and rear suspension.

• Check the en re front and rear shock absorber assembly for
Inspec on of leakage, damages or loosened fasteners.
Suspension System • Check for free travel distance between the front shock absorbers
and rear shock absorbers.
• Check transaxle for fluid leakage.

• Check steering wheel for free play.

Inspec on of • Check for steering difficulty and unususal noises.

Steering system • Check steering linkage for looseness or damage.
• Check ball joints and steering gear.

• Check coolant level in coolant reservoir.

• Check accelerator handle for smooth opening and automa c
Inspec on of
rese ng at all steering posi ons of the steering handle.
Cooling system
• Check the accelerator handle cable if accelerator handle cannot be
reset as usual.

Con nued...

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• Check head lights, stop lights, le and right turn signal lights, tail
lamps.
• Check headlights alignment.
• Check if brake lamp turns on when brake is applied.
Inspec on of • Check the light intensity and flashing.
Lights • Check if switching between high and low beams are normal.
and other
accessories • Check if the horn sound is normal.
• Check windshield glass for scratches, windshield washer fluid level
and spray.
• Check wiper opera on.
• Check AC, AC hoses for leakage and damage.

• Check ba eries for normal performance.

• Check electrolyte level.
Inspec on of
• Check charge.
Ba eries
• Check terminals and ba ery compartment.
• Test ba eries.

• Check motor system.

• Check hall cable-sensor, sensor connector, power supply.
• Check hall motor connector and controller connector.
• Check FOC controller:
◦ Indicator for flashing frequency for warnings.
◦ Power input.

Inspec on of ◦ ACC wire of alarm for closed circuit.

electrical system • Check DC-DC convertor power input and output.
• Check power-lock.
• Check ECU.
• Check side stand switch.
• Check brake switch.
• Check charging port.
• Check display as per the diagnos c code.

Fig. 5.2.13 Steps to Carry out On-Vehicle Inspec on of Four-Wheeler EVs

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5.2.4.2 Carry out Rou ne Service and Repairs on a

Four-Wheeler EV
A er carrying out on-vehicle inspec on and through DTC check, a note of all the parts that are damaged,
worn out, contaminated, malfunc oning, etc. should be made. If some of the faults are beyond the
scope of EVST, then it has to be escalated to the Lead Technician. All other servicing and repair work can
be carried out as per OEM instruc ons. The Service Technician should wear the required PPE, follow all
safety precau ons and use appropriate tools to work. To perform servicing and repair work, the first step
is to remove the external parts to gain access to the internal parts. Next, the internal parts have to be
inspected to see if there are any faults, find the cause, take remedial ac on and then reinstall all the
parts back in its place.

5.2.4.3 Diagnosis of Faults in a Four-Wheeler EV

Diagnosis of fault in vehicle components is carried out by finding the fault by means of its symptoms,
appearance, conduc ng tests using measuring devices, applying knowledge, etc. The cause for the fault
has to be determined and then remedial ac on has to be taken. Technicians should analyse the reason
for faults or failure. For example: if a part is worn out, then it should be analysed to see if it was due to
normal wear and tear or due to other abnormal condi ons like shock, fa gue, overloading, improper
lubrica on, improper maintenance, etc. the most common reasons for a part failure are:
• Poor preven ve maintenance or inspec ons.
• Poor design of the part.
• Improper use of the part.
• Wrong usage or driver abuse.
Some of the common faults observed in a Four-wheeler EV is listed below:

• Tyre/tyres pressure is too low or insufficient.

• Air leakage from tyres.
• Axle is deflected.
• Improper wheel alignment.
• Wheel/wheels are deformed and tyre/tyres are deflected.
Wheels and tyres • Wheel/wheels vibrate.
• Axle bearing is loosened.
• Tyre/tyres are deteriorated.
• Wheel/wheels are difficult to turn.
• Axle bearing has failed.
• Braking is bad.

Con nued...

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• Steering column is damaged.

Steering system • Steering wheel is difficult to turn and unusual noises.
• Steering is unstable.

• Worn out or loose springs and linkages.

• So ening of shock absorber.
• Insufficient spring elas city.
• Oil leakage from shock absorber.
• S ffness in shock absorber spring.

Suspension • Hardened shock absorber.

system • Deflec on in shock absorber rod.
• Abnormal noise from suspension.
• Failure of shock absorber.
• Abnormal noise from shock absorber.
• Insufficient fluid in shock absorber.
• Shock absorber bolts are loosened.

• Poor brake performance.

• Failure of hydraulic disc brake.
• Brake assembly not installed properly.
• High or low level of brake fluid in the main brake pump
reservoir.
• Blockage of fluid flow channel.
• Air leakage in brake caliper, brake hose and hose joint.
• Sponge-like feeling while opera ng brake handle.
• Presence of air in brake system oil circuit.
Brake system
• Wearing of brake disc and brake pad.
• Deforma on and bending of brake pad.
• Contamina on of brake disc and brake pad.
• Excessive wearing or damage in main brake pump piston
surface and oil cylinder wall surface.
• Cracks, damages and wearing out of main brake piston cup.
• Excessive wearing or damage in brake caliper pump piston
surface and oil cylinder wall surface.
• Abnormal noise from the brake.

Fig. 5.2.14 Common Faults Observed in Four-Wheeler EVs

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5.2.5 Post Rou ne Service and Repairs on a Four-Wheeler EV

A er comple ng servicing/repair work, the cable connector, nuts, bolts and fasteners and control
switches have to be inspected.

• Check cables a er clamping to ensure electric safety.

• Cables should be bound with adhesive tapes at the
designated posi ons.
• Cables should not be placed at end of screws, bolts and
vehicle frame end.
Inspec on of • Protect cables at a sharp angle or turning posi on with
Cable connector adhesive tapes.
• Cables should be placed without twis ng or tying.
• Controlling cables should not be bent or twisted.
• Ensure that the connector shroud is not damaged or the
connector is not excessively open before connec ng.

• Check if all nuts, bolts and fasteners on the chassis are

Inspec on of ghtened as per the torque values.
nuts, bolts and
fasteners • Check if safety clips, split pins, cables and hose clamps are
placed properly and secured ghtly.

• Head lights, tail lights and Indicators

• Accelerator
• Horn
Inspec on of
• Brake
Control switches
• Igni on switch
• Display panel
• Telema cs Control Unit (TCU)

Fig. 5.2.15 Post Service/Repairs Inspec on in Four-Wheeler EVs

A er the comple on of work, all the tools and spare parts have to be returned. All the waste generated
should be segregated and disposed in a safe manner as per the company procedures. The vehicle has to
be re-energized. Assist EVSLT in diagnosis of faults a er servicing/repairing. The serviced/repaired
vehicle has to be visually examined as per OEM manual and checked for warning signals, unusual noises,
vibra ons, etc. and then taken for a test ride to check if the vehicle is running at normal levels and
servicing and repairs are successful. Carry out tests using measuring devices if required and compare the
test results with the vehicle specifica ons and regula ons. If certain issues are no ced, seek the advice
of seniors and rec fy the problems by performing addi onal repairs.

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5.2.6 Documenta on
Documenta on helps in keeping track of all the work carried out. It is a good prac ce to keep a record of
the vehicle model number, serial numbers, parts, specifica ons of all the components, etc. Keeping
record of components will help in future to understand its performance, life, wear and tear frequency,
problems if any, etc. Documenta on of the work done will provide data base for future troubleshoo ng
and also planning, as it helps to calculate the man hours taken to solve a certain issue. Documenta on is
also important for legal and organiza onal requirements. A Repair Order is the most common form of
documenta on used in the workshop to document servicing or repair work carried out.

Fig.5.2.16 Sample Record Order

(Source: Vehicle Maintenance Pro)

Notes

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5.2.7 Health and Safety Measures

It is important to follow health and safety measures at workplace to protect men, material and
machines. Every organisa on has to be complaint with health and safety guidelines provided by the
State and legal authori es. Electric vehicles comprise of high-voltage components and other aggregates
that require safe handling to prevent injuries, death or damage to equipment and workplace. It is
important to make note of all the safety measures outlined by the manufacturers. A workshop poses
many risks like electric shocks, fire, explosion, exposure to ba ery acids, fumes, slips and falls, etc. Some
of these risks can also pose problems to components and equipment like corrosion, damage,
deforma on, etc. the presence of HV components can be a threat to other components inside and
outside the vehicle. Therefore, it has to be ensured proper insula on and handling techniques are
followed. Workers should wear appropriate PPE, use insulated and recommended tools and follow safe
prac ces. Employees should be trained in proper disposal of hazardous, non-hazardous and recyclable
wastes to prevent damage to humans, workplace and environment.

Summary
• Conven onal vehicles which run on petrol/diesel use an Internal Combus on Engine (ICE), whereas
EVs use electrical energy stored inside a high voltage ba ery for propulsion of the vehicle.
• The main mechanical components in electric and hybrid Four-wheeler vehicles are chassis and
body, drive train, brake system, suspension system, steering system, wheels and tyres, internal
combus on engine, fuel supply system, exhaust system and cooling system.
• The main mechanical components in electric and hybrid Four-wheeler vehicles are OBC, Inverter,
DC-DC convertor, electric motor, HV ba ery, power distribu on unit.
• An Electric Vehicle consists of four major subsystems, body design, energy source, propulsion
system and auxiliaries. The main working mechanism of the vehicle is based on the energy source
and the propulsion system.
• A pure electric Four-Wheeler is powered by a ba ery and does not use fuels like petrol and diesel.
These vehicles do not use fuel hence, they are zero emission vehicles.
• Hybrid electric vehicles use both electrical power and ICE to propel the vehicle.
• Plug-in hybrid electric vehicles use both electrical power and ICE to propel the vehicle like HEVs, but
the difference between them is that PHEVs use electrical power as the main driving force.
Therefore, they require higher capacity ba eries than HEVs.
• Fuel-cell electric vehicles have hydrogen fuel cells that use chemical reac ons to produce electricity
which in turn propels the vehicle.
• Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security
has to be followed. The job card has to be obtained and the work that needs to be done has to be
analysed and understood. All the technical data required should be obtained from OEM manuals
and from the Lead Technician.
• The various tools and equipment used in maintenance, servicing and repairing of EVs can be broadly
classified as tools, tes ng equipment and workshop equipment.
• It is important to know the specifica ons of the vehicle before taking up any work on the vehicle.
This will help to check if all the parameters are as specified and makes fault finding easier.

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• Pre-service visual inspec on helps the service team to assess the problems/faults in the vehicle in
addi on to customer complaints. This also helps to organize for the tools, spare parts and other
equipment that are likely to be required.
• The faults in a vehicle can be diagnosed either using the DTC (Diagnosis Trouble Code) or manually
based on the symptoms. In the DTC process, the malfunc oning part is iden fied using a process of
elimina on and the possible trouble area are eliminated one a er the other using the so ware and
inspec on of related parts.
• In the DTC check it is important to know if the problem s ll occurs or has occurred in the past and
returned to normal. The DTC should be compared with the problem symptom to check if they are
related.
• It is most difficult to troubleshoot when no problem symptom occurs, which requires a thorough
problem analysis. A simula on in similar condi ons and environment in which the problem
occurred in the vehicle should be carried out.
• A er carrying out on-vehicle inspec on and through DTC check, a note of all the parts that are
damaged, worn out, contaminated, malfunc oning, etc. should be made. If some of the faults are
beyond the scope of EVST, then it has to be escalated to the Lead Technician. All other servicing and
repair work can be carried out as per OEM instruc ons.
• Diagnosis of fault in vehicle components is carried out by finding the fault by means of its symptoms,
appearance, conduc ng tests using measuring devices, applying knowledge, etc. The cause for the
fault has to be determined and then remedial ac on has to be taken.
• A er comple ng servicing/repair work, the cable connector, nuts, bolts and fasteners and control
switches have to be inspected.
• A er the comple on of work, all the tools and spare parts have to be returned. All the waste
generated should be segregated and disposed in a safe manner as per the company procedures. The
vehicle has to be re-energized and taken for a test ride.
• Documenta on helps in keeping track of all the work carried out. It is a good prac ce to keep a
record of the vehicle model number, serial numbers, parts, specifica ons of all the components,
etc. Keeping record of components will help in future to understand its performance, life, wear and
tear frequency, problems if any, etc.
• It is important to follow health and safety measures at workplace to protect men, material and
machines. Every organisa on has to be complaint with health and safety guidelines provided by the
State and legal authori es. Electric vehicles comprise of high-voltage components and other
aggregates that require safe handling to prevent injuries, death or damage to equipment and
workplace.

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Exercise
Answer the following ques ons:
1. Explain the different technologies of a Four-wheeler EV.
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
2. Briefly discuss the steps to be taken while performing servicing/repair work on a Four-wheeler EV.
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

www.youtube.com/watch?v=XtWvIEDQXLA www.youtube.com/watch?v=nqD32G6gUQI
Disconnec ng High Voltage in Insula on Tes ng on Hybrid Vehicles
Electric/Hybrid vehicles

www.youtube.com/watch?v=t_jDdsC5UBc www.youtube.com/watch?v=FeK_ZpkIxn8
Working on high voltage vehicles What does an EV Service look like?

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6. Perform rou ne
service and repairs
of a 2/3 wheeler
EV

Unit6.1 - Basics of Electric 2/3-Wheeler Vehicle

Unit6.2 - Rou ne Service and Repairs on a 2/3-Wheeler
EV

ASC/N1451
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Key Learning Objec ves

At the end of this module, the trainee will be able to:
1. Demonstrate preparatory ac vi es for diagnosing faults and repairing of a 2/3 wheeler EV
2. Demonstrate how to use different techniques for diagnosing faults and repairing the 2/3 wheeler
vehicle

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Unit 6.1 - Basics of 2/3-Wheeler EV

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. List various components /aggregates and the manufacturer's specifica ons of a 2/3 wheeler EV
2. Discuss basic technology used, func oning and interconnec ons of various systems and components
of a 2/3 wheeler EV

6.1.1 Basics of 2/3-Wheeler EVs Anatomy

Electric 2/3-wheelers are plug-in electric vehicles with two or three wheels. The electricity is stored in a
rechargeable ba ery which drives one or more motors. Most of these EVs are powered by Lithium-ion
ba eries and they can be charged by plugging into ordinary wall outlets.
The main mechanical components in an EV are:

Chassis

Body

Drive train

Brake system

Suspension system

Steering system

Wheels and Tyres

Fig. 6.1.1 Main Mechanical components in a 2/3-Wheeler EV

Chassis: The Chassis of 2/3-wheelers holds together the body, motor, engine, ba eries, suspension,
steering handle bars, seat, wheels, tyres, etc. It bears the weight of the whole vehicle along with weight
of the people riding and any addi onal load like luggage and cargo. It also withstands the stresses during
accelera on, braking and bad road condi ons.

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(a) (b)
Fig. 6.1.2 (a). Chassis of a 2-Wheeler EV and (b). Chassis of a 3-Wheeler EV
(Source: www.indiamart.com)

Body: It is the super-structure of a vehicle and is a ached to the chassis.

Le Right/
Body Panel Windshield
Saddle Front Neck Cover
Front Central
Front Panel
Rear Le / Cover
Right Handrail Headlight
Tail light
Ba ery Front Fender
Cover
Rear
Fonder

Le /Right Le /Right Front Le /

Central Cover Side Panel Right Panel
Rear Central Cover Footrest
Fig. 6.1.3 E-Scooter body (Source: Jiangsu Niu Electric Technology Co. Ltd, www.myniu.org)

Fig. 6.1.4 Cargo Rikshaw Body (Source: www.kine cgreenvehicles.com)

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Drivetrain: The main func on of the drivetrain is to deliver the power generated by the engine and
motor to the drive wheels. It consists of the torque converter, transmission, propeller sha , differen al
and axles.

Fig. 6.1.5 Drivetrain in a 2-Wheeler EV (Source: www.researchgate.net)

Fig. 6.1.6 Drivetrain in a 3-Wheeler EV (Source: www.seman cscholar.org)

Suspension: The suspension system consists of tyres, springs, shock absorbers and linkages that
connects a vehicle to the wheels. It helps in vehicle's road-holding, braking, providing comfort, reducing
stress on the vehicle due to road shocks and provides the required height to the vehicle.

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Fig. 6.1.7 (a) Suspension System of Two and Three-Wheeler

Fig. 6.1.7(b) Front Wheel Suspension System (Source: www.indiamart.com)

Fig. 6.1.7(c) Rear Wheels Suspension System (Source: www.alibaba.com)

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Steering: It contains the steering handle, steering column, gears, linkages, etc. It helps the driver to
control and turn the vehicle, provides stability to the vehicle, reduces vibra ons and wear and tear of
tyres.

Fig. 6.1.8 Steering and Front Suspension in a 3-Wheeler EV (Source: EZGo Technicians repair manual)

Brakes: Most of the three-wheelers are fi ed with drum brakes (internal expansion) and disc brakes are
commonly used in Two-wheelers. Drum brakes are commonly operated mechanically by means of steel
cable/rod in Two or Three-wheelers. Disc brakes are operated hydraulically by the master cylinder,
calliper, and discs.

Fig. 6.1.9 Disc and Drum Brakes

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Fig. 6.1.10 Two and Three-Wheeler Braking System

Wheel and tyres: As the name indicate, 2 wheelers have two wheels, the front and the back wheel and 3
wheelers have three wheels, one front wheel and two back wheels. The wheels of a vehicle are mounted
on a hub and consists of the rim, tyre and tube. It helps in suppor ng the weight of the vehicle, absorbs
road shocks, grip the road surface and balance the vehicle in mo on and rest. Tyres are mounted on the
wheel rim. It provides good grip, carries the load of the vehicle, absorbs road shocks, reduces vibra ons
and gives cushioning effect to the vehicle.

Fig. 6.1.11 Wheels and Tyres in a 3-Wheeler EV

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The main electrical components in a 2/3-wheeler EV are:

Name of the electrical Image

component

Ba ery

Lithium-ion ba ery (Source: www.indiamart.com)

Motor

Brushless DC motor (Source: www.indiamart.com)

Control units

(Source: www.alibaba.com)

OBC

(Source: www.bazaar.shopclues.com)

Charging points

(Source: www.india mes.com)

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Name of the electrical Image

component

Inverter (DC-DC converter)

(Source: www.amazon.com)

BMS

(Source: www.financialexpress.com)

Table 6.1.1 Main Electrical Components in a 2/3-Wheeler EV

6.1.2 Basic Technology of 2/3-Wheeler EVs

Fig. 6.1.12 Basic Technology of 2/3-Wheeler Evs (Source: h ps://www.techsciresearch.com)

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Like in all EVs, ba eries, motor and motor controller unit are the main components which drive the
electric 2/3-wheelers. These electrical components are connected to the transmission system. The
rechargeable ba eries are the energy source which are charged by taking electric current from the grid.
The controller unit then controls the flow of energy from the ba ery to the motor. The motor in turn
transmits the power to the wheels of the vehicle with the help of the transmission system or directly to
the wheel (in-wheel motor).

6.1.3 Interconnec ons of various components in

2/3-Wheeler EVs
The following figure shows the generic block diagram and wiring diagram of an Electric 2-wheeler:

Fig. 6.1.13 Block Diagram of 2-Wheeler EVs (Source: www.irjet.net)

Fig. 6.1.14 (a) Wiring Diagram of 2-Wheeler Evs (Source: www.support.electricscooterparts.com)

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Fig. 6.1.14 (b) Wiring Diagram of 2-Wheeler Evs (Source: www.researchgate.net)

The following figure shows the generic block diagram and wiring diagram of an Electric 3-wheeler:

Fig. 6.1.15 Block Diagram of 3-Wheeler EVs (Source: www.irjet.net)

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Fig. 6.1.16 Wiring Diagram of 3-Wheeler EVs (Source: www.evcra .com)

Notes

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Unit 6.2 - Rou ne Service and Repairs on a 2/3-Wheeler EV

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. List the types of tools and equipment used in different processes of a 2/3 wheeler EV maintenance
2. List the ac vi es need to perform for preparing a 2/3 wheeler EV for fault iden fica on and repairing
work
3. Discuss the symptoms of technical faults, their causes and rec fica on procedures in a 2/3 wheeler
EV
4. Explain the health and safety measures and regula ons w.r.t. equipment and components during
fault diagnosis

6.2.1 Prepare to Perform Rou ne Service and Repairs on

a 2/3-Wheeler EV
Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security must
be followed. The job card must be obtained and the work that needs to be done has to be analysed and
understood. All the technical data required should be obtained from OEM manuals and from the Lead
Technician. It is a legal requirement for EV workshops to protect its people and workplace from poten al
risks especially while dealing with High-Voltage components. This can be achieved by carrying out risk
assessment, training of workers in safe work prac ces and maintain safe work environment.

6.2.1.1 Guidelines for Service/Repair of 2/3 Wheeler EVs

Only trained personnel should carry work on Evs.

Always wear appropriate PPE for the work being carried out.

Always use recommended tools and equipment.

Always follow OEMs instruc ons during servicing, maintaining and repairing of the vehicle.

Ensure that the place where maintenance is being carried out is well ven lated and
authorized area.

Remove keys from the key switch and remove the ba ery wire before any work.
Con nued...

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Deenergize the system as per OEM instruc ons.

Always use correct ways of handling HV components.

Always use insulated tools while working on electrical components.

Always check the polarity of the ba ery terminal and rewire correctly.

Always use OEM approved spare parts while replacing parts.

Li , hoist and secure the vehicle as per the OEMs recommenda on.

Always block chassis before working underneath it.

Always carry out maintenance work away from sources of exposed flame.

Replace missing or damaged warning, informa on or cau on labels.

Be aware of the common risks in workshops and steps to prevent them.

Be aware or emergency response techniques.

Be aware the procedures to record and report faults that cannot be rec fied by self.

Always maintain documents of all the work carried out on the vehicle.

Fig. 6.2.1 Guidelines for Service/Repair of 2/3-Wheeler EVs

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6.2.1.2 Specifica ons of the vehicle

It is important to know the specifica ons of the vehicle before taking up any work on the vehicle. This
will help to check if all the parameters are as specified and makes fault finding easier. Apart from
diagnosis, it will also help to cross-check the parameters a er servicing.

Note: Refer to the OEM manual for the specifica ons related to a par cular Model of the vehicle.

Some of the overall specifica ons are:

Dimensions of the vehicle Dimensions of the vehicle including ground clearance.

Type of vehicle frame.

Wheel and tyre:
Ÿ Specifica ons of front tyre
Ÿ Type of front rim
Ÿ Air pressure of front tyre
Ÿ Specifica on of rear tyre/tyres
Ÿ Type of rear wheel/wheels
Ÿ Air pressure of rear tyre/tyres

Suspension system:
Ÿ Front shock absorber
Ÿ Back shock absorber

Brake:
Ÿ Type of front brake
Ÿ Type of rear brake

Fig. 6.2.2 Overall Specifica ons of 2/3-Wheeler EVs

Some of the motor and motor controller system specifica ons are:

Motor:

Ÿ Motor type
Ÿ Controller type
Ÿ Rated voltage
Ÿ Rated power
Ÿ Maximum motor power
Ÿ Maximum motor torque

Con nued...

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Controller:

Ÿ Rated voltage
Ÿ Undervoltage protec on
Ÿ Maximum current of the controller
Fig. 6.2.3 Motor and Motor Controller System Specifica ons of 2/3-Wheeler EVs

Some of the ba ery and ba ery charger system specifica ons are:

Ba ery:

Ÿ Ba ery type
Ÿ Rated voltage
Ÿ Rated capacity

Charger:

Ÿ Rated output voltage

Ÿ Rated output current

Fig. 6.2.4 Ba ery and Ba ery Charger System Specifica ons of 2/3-Wheeler EVs

Some of the braking system specifica ons are:

Diameter of front brake disc

Thickness of front brake disc

Thickness of front brake pad
Diameter of rear brake disc

Thickness of rear brake disc

Thickness of rear brake pad

Brake fluid

Fig. 6.2.5 Braking System Specifica ons of 2/3-Wheeler EVs

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Some of the ligh ng and display specifica ons are:

Head light

Rear tail lamp/lamps

Turning signal lights
Brake light

Display
USB charging interface
Central control unit

Fig. 6.2.6 Ligh ng and Display Specifica ons of 2/3-Wheeler EVs

Notes

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6.2.2 Tools and Equipment

The various tools and equipment used in maintenance, servicing and repairing of EVs can be broadly
classified as tools, tes ng equipment and workshop equipment.

Tools Image

Spanner is used to provide grip

while applying torque to objects like
nuts and bolts. The most common
type of spanners are open and ring
spanners.

Socket wrench is a type of spanner

that has a closed socket format.

Screw drivers are used to removing

and installing screws. They can be
manually operated or power
operated.

Pliers and Wire cu ers are used to

grip small objects, hold wires, bend
wires and loops and a ach wires.
They can also be used to cut wires
with minimal damage to the
insula on or internal conductors.

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Tools Image

Hex or Allen key wrenches are used

to drive bolts and screws with a
hexagonal socket.

Source: www.amazon.com

Tyre spoon levers are used to

separate tyres from the wheels.

Source: www.amazon.com

Adjustable locking spanner

wrenches are used to grip fasteners
like nuts and bolts of all sizes.

Source: www.amazon.com

Torque wrenches are used to apply

a specific torque to nuts and bolts.

Source: www.ubuy.com

Con nued...

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Tools Image

Impact wrenches are used to deliver

high torque output with minimal
exer on by the user. They are used
along with impact sockets.

Source: www.indiamart.com

Bearing pullers are used to remove

components like gears, pulleys,
bearing, etc. from sha s.

Source: www.engineeringtools.com

Tyre pressure gauges are used to

measure the pressure in inflated
tyres on the wheels of vehicles.

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Tools Image

Measuring equipment

Vernier calipers are used to

measure the inner and outer
dimensions of objects.

Micrometers are used to measure

thickness, diameter and length of
solid objects.

Feeler gauges are used measure the

gap between two parts.

Source: www.amazon.com

Mul meters are also known as

Volt/Ohm meter or VOM, they are
used to measure voltage, resistance
and current

Dial gauges are used to measure

minute lengths and displacement
accurately.

Source: www.upload.wikimedia.org
Con nued...

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Tools Image

Ba ery hydrometers are used to

measure the specific gravity
(density) of the ba ery's electrolyte,
which helps in determining the state
of charge of the ba ery.

Source: www.indiamart.com

Ba ery maintenance kits contain

insulated tools and other devices
required for ba ery maintenance.

Workshop equipment

Electric drills or power drills are

used to make a hole in a variety of
materials and also to drive screws
through different materials.

Cranes are used to li and lower or

move material and objects
horizontally with help of hoist
chains and cables.

Source: www.eurocarparts.com

Con nued...

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Tools Image

Ramps and hoists are used to li

vehicles so that repair and
maintenance works on the
undercarriage of vehicles can be
carried out.
Source: www.eurocarparts.com

Jack and axle stand is used to

support the weight of vehicles and
hold it in place while replacing tyres
and other parts under the vehicle.

Wheel chocks are used to prevent

the move movement of wheels
while servicing the vehicle.

Source: www.indiamart.com

Table 6.2.1 Tools, Measuring Devices and Workshop Equipment

6.2.3 Visual Inspec on of 2/3-Wheeler EVs

Pre-service visual inspec on helps the service team to assess the problems/faults in the vehicle in
addi on to customer complaints. This also helps to organize for the tools, spare parts and other
equipment that are likely to be required. The vehicle has to be set on a flat ground before inspec on.
Inspec on of the following parts of the vehicle has to be carried out:

Part Inspec on item Inspec on observa on

Appearance Outer parts

Screws, fasteners, nuts and

bolts

Front and rear shock

absorbers

Damages, deforma ons, etc.

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Part Inspec on item Inspec on observa on

Fixed assembling Lock and hook

Steering

Front and rear tyres

Front and rear wheels and wheel-hub

assembly

Front and rear axles

Handles and handrail

Braking system Appearance

Assembly clearance

Abnormal brake noise

Brake fluid volume

Response me

Braking distance

Electronic Ligh ng
components
Power lock

Instrument

Vehicle insula on

Alarm and horn

EBS energy recovery

Controller

Wheel-hub motor Appearance and wire connec on

Startup

Abnormal noise

Tolerance

Deforma on

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Part Inspec on item Inspec on observa on

So ware Display so ware version

ECU so ware version

FOC so ware version

BMS se ng

Table 6.2.2 Checklist for Visual Inspec on of 2/3-Wheeler EVs

6.2.3.1 Steps to carry out inspec on

• Check accelerator handle for smooth opera on.
Inspec on of • Check accelerator handle for smooth opening and automa c rese ng
Accelerator at all steering posi ons of the steering handle.
handle • Check the accelerator handle cable if accelerator handle cannot be
reset as usual.

• Check connec on of brake handle for looseness, excessive free travel or

Inspec on of other damages.
Brake system • Check brake shoes/pads for wearing.
• Check brake fluid level.

• Operate front brake and check front suspension system by pressing

down the handle bar several mes to check mo on of the fork.
• Check the en re front shock absorber assembly for leakage, damages or
Inspec on of loosened fasteners.
Suspension • Operate rear brake and check rear suspension system by pressing down
System the handle bar several mes to check mo on of the fork.
• Check the en re rear shock absorber assembly for leakage, damages or
loosened fasteners.
• Check for free travel distance between the rear shock absorbers.

• Li the scooter up with central stands.

Inspec on of
• Check the side stand spring for tension loss or damages.
Side stand
• Check the side stand assembly for free movement.

Inspec on of • Li the scooter up with central stands.

Steering • Li up the front wheel off the ground.
column • Check if the handle can be turned freely to the le and right sides.

Con nued...

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• Check the steering column bearing if scooter handles are not moving
smoothly.
Inspec on of • Check the steering column bearing for wearing by moving the fork back
Steering and forth.
column • Check the steering column bearing if the steering column is displaced
ver cally.

• Li the scooter up with central stands.

• Li up the front/rear wheels to check range of free travel.
• Check the wheel bearings for wearing by holding the front/rear wheel
and try to move it le ward and rightward.
Inspec on of • Check if the wheel bearings have loosened.
Wheels and • Turn the wheel to make sure that it can be rotated smoothly without any
Tyres abnormal noise.
• Check tyre pressure with pressure gauge.
• Check tyres for cuts, damages or embedded sharp objects.
• Check tread depth.
• Check flatness of front and rear wheels.

• Turn on the igni on switch and check the right and le combina on
switches.
• Check head light.
• Check le and right turn signal lamps.
Inspec on of • Check tail lamp.
Lights • Check the light intensity and flashing.
and electrics • Check if switching between high and low beams are normal.
• Check if brake lamp turns on when brake is applied.
• Check if the horn sound is normal.
• Check for normal opera on of startup bu on.
• Check for normal opera on of speed regula on switch.

• Check ba ery for normal performance.

• Check motor system.
• Check hall cable-sensor, sensor connector, power supply.
• Check hall motor connector and controller connector.
• Check FOC controller:
Inspec on of ◦ Indicator for flashing frequency for warnings.
electrical ◦ Power input.
system ◦ ACC wire of alarm for closed circuit.
• Check DC-DC convertor power input and output.
• Check power-lock.
• Check ECU.
• Check side stand switch.

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Inspec on of • Check brake switch.

electrical • Check charging port.
system • Check display as per the diagnos c code.

Fig. 6.2.7 Steps to Carryout Inspec on of 2/3-Wheeler EVs

6.2.4 Perform Rou ne Service and Repairs on a

2/3-Wheeler EV
A er carrying out inspec on of the vehicle, a note of all the parts that are damaged, worn out,
contaminated, malfunc oning, etc. should be made. If some of the faults are beyond the scope of EVST,
then it has to be escalated to the Lead Technician. All other servicing and repair work can be carried out
as per OEM instruc ons. The Service Technician should wear the required PPE, follow all safety
precau ons and use appropriate tools to work. To perform servicing and repair work, the first step is to
remove the external parts to gain access to the internal parts. Next, the internal parts must be inspected
to see if there are any faults, find the cause, take remedial ac on and then reinstall all the parts back in
its place.

6.2.4.1 Dismantle all the External Parts of a

2/3-Wheeler Vehicle
The following are the parts to be removed to carry out inspec on of the internal parts of the vehicle (it is
indica ve process. Please follow the sequence suggested by the OEM):
Ÿ Remove windshield by unscrewing the screws.
Ÿ Remove front neck cover.
Ÿ Remove front panel.
Ÿ Remove the screws and li up under seat storage compartment.
Ÿ Disconnect the connectors and pull ba ery compartment lock cable.
Ÿ Remove rear central cover.
Ÿ Remove the footrest and ba ery compartment cover.
Ÿ Remove the side panels.
Ÿ Remove the hand rail.
Ÿ Remove end cap and ba ery cover.

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Ÿ Pull-out whole-body panel.

Ÿ Remove le /right central cover
Ÿ Remove foot pegs.
Ÿ Remove le /right panels.
Ÿ Remove front central cover.
Ÿ Unplug USB output cable.
Ÿ Unplug power lock connector and remove power lock.
Ÿ Remove front wheel cover.
Ÿ Unplug dashboard cable and remove display.
Ÿ Plug the brake connector and remove front/rear brake system.
Ÿ Remove side stand and side stand switch.
Ÿ Remove front/rear fenders.
Ÿ Remove the motor connectors on FOC (field-oriented control) controller.
Ÿ Remove the motor.

6.2.4.2 Diagnosis of Faults in a 2/3-Wheeler EV

Diagnosis of fault in vehicle components is carried out by finding the fault by means of its symptoms,
appearance, conduc ng tests using measuring devices, applying knowledge, etc. The cause for the fault
has to be determined and then remedial ac on has to be taken. Technicians should analyse the reason
for faults or failure. For example: if a part is worn out, then it should be analysed to see if it was due to
normal wear and tear or due to other abnormal condi ons like shock, fa gue, overloading, improper
lubrica on, improper maintenance, etc. the most common reasons for a part failure are:
• Poor preven ve maintenance or inspec ons.
• Poor design of the part.
• Improper use of the part.
• Wrong usage or driver abuse.
Some of the common faults observed in a 2/3-wheeler EV is listed below:

• Tyre pressure is too low or insufficient

• Air leakage from tyre
Front wheel • Axle is deflected
• Wheel deformed and tyre is deflected
• Wheel vibrates/wobbles

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• Axle bearing is loosened

• Tyre is deteriorated
Front wheel • Wheel is difficult to turn
• Axle bearing has failed
• Braking is bad

• Front fork is deflected

• Abnormal noise from front shock absorber
Front fork • Insufficient fluid in front shock absorber
• Shock absorber bolts are loosened

• Steering handle is damaged

Steering handle • Steering handle is difficult to turn
• Steering is unstable

• Rota on of rear wheel is irregular

• Failure of motor
• Worn out or loose bearing
• Insufficient or excess tyre pressure
• So ening of shock absorber
Rear wheel, rear • Insufficient spring elas city
suspension and motor • Oil leakage from shock absorber
• S ffness in the rear shock absorber spring
• Hardened shock absorber
• Deflec on in shock absorber rod
• Abnormal noise from rear suspension
• Failure of the shock absorber

• Poor brake performance

• Failure of hydraulic disc brake
• Brake assembly not installed properly
Brake system • High or low level of brake fluid in the main brake reservoir
• Blockage of fluid flow channel
• Air leakage in brake caliper, brake hose and hose joint
• Sponge-like feeling while opera ng brake handle

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• Presence of air in brake system oil circuit

• Wearing of brake disc and brake pad
• Deforma on and bending of brake pad
• Contamina on of brake disc and brake pad
• Excessive wearing or damage in main brake pump piston
Brake system surface and oil cylinder wall surface
• Cracks, damages and wearing out of main brake piston cup
• Excessive wearing or damage in brake caliper pump piston
surface and oil cylinder wall surface
• Abnormal noise from the brake

Fig. 6.2.8 Common Faults Observed in 2/3-Wheeler EVs

6.2.4.3 Causes and remedies for some important faults

The following table shows the causes and remedies for some of the important faults in 2/3-Wheeler EVs:

Fault Cause Remedy

Front wheel vibrates/wobbles Damaged wheels, improper Replace damaged wheels,

wheel and tyre balance, perform wheel alignment,
uneven wearing of tyre, replace worn out tyres Adjust
improper tyre pressure, loose tyre pressure, ghten of lug
lug nuts, etc. nuts, etc.

Wheel is difficult to turn Worn out spindle bearing Replace the spindle bearing

Steering handle is difficult to Steering column bearing is Loosen the steering column
turn too ght, Internal bearings of bearing, clean and adjust
Steering is unstable steering column are clogged steering column, replace
with debris, damaged damaged damper
steering damper

Rota on of rear wheel is Improper wheel balancing, Perform wheel balancing,

irregular damaged wheels, improper replace damaged wheels,
transmission, improper tyre check transmission, adjust
pressure, etc. tyre pressure

Poor brake performance Damaged brake cables, Replace all damaged cables,
damaged components, components and torsion
corrosion and damage to springs, correct brake se ngs
torsion spring, improper
se ngs

Table 6.2.3 Causes and Remedies for Some Important Faults

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6.2.5 Post Rou ne Service and Repairs on a 2/3-Wheeler EV

A er comple ng servicing/repair work, the cable connector, nuts, bolts and fasteners and control
switches have to be inspected.

• Check cables a er clamping to ensure electric safety.

• Cables should be bound with adhesive tapes at the
designated posi ons.
• Cables should not be placed at end of screws, bolts and
vehicle frame end.
Inspec on of Cable connector • Protect cables at a sharp angle or turning posi on with
adhesive tapes.
• Cables should be placed without twis ng or tying.
• Controlling cables should not be bent or twisted.
• Ensure that the connector shroud is not damaged or the
connector is not excessively open before connec ng.

• Check if all nuts, bolts and fasteners on the chassis are

ghtened as per the torque values.
Inspec on of nuts, bolts
• Check if safety clips, split pins, cables and hose clamps are
and fasteners
placed properly and secured ghtly.

• Head lights, tail lights and Indicators

• Accelerator
• Horn
Inspec on of Control switches • Brake
• Igni on switch
• Display panel
• Telema cs Control Unit (TCU)

Fig. 6.2.9 Post Service/Repairs Inspec on in 2/3-Wheeler EVs

A er the comple on of work, all the tools and spare parts have to be returned. All the waste generated
should be segregated and disposed in a safe manner as per the company procedures. The vehicle has to
be re-energized. Assist EVSLT in diagnosis of faults a er servicing/repairing. The serviced/repaired
vehicle has to be visually examined as per OEM manual and checked for warning signals, unusual noises,
vibra ons, etc. and then taken for a test ride to check if the vehicle is running at normal levels and
servicing and repairs are successful. Carry out tests using measuring devices if required and compare the
test results with the vehicle specifica ons and regula ons. If certain issues are no ced, seek the advice
of seniors and rec fy the problems by performing addi onal repairs.

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6.2.6 Documenta on
Documenta on helps in keeping track of all the work carried out. It is a good prac ce to keep a record of
the vehicle model number, serial numbers, parts, specifica ons of all the components, etc. Keeping
record of components will help in future to understand its performance, life, wear and tear frequency,
problems if any, etc. Documenta on of the work done will provide data base for future troubleshoo ng
and also planning, as it helps to calculate the man hours taken to solve a certain issue. Documenta on is
also important for legal and organiza onal requirements. A Repair Order is the most common form of
documenta on used in the workshop to document servicing or repair work carried out.

Repair Order

Reason for repair: Date:__________________

________________________________________ Name: __________________________________
________________________________________ Address: ________________________________
________________________________________ ________________________________________
________________________________________ ________________________________________
Instruc ons: Vehicle Regn.no. __________________________
________________________________________ Model__________________________________
________________________________________ Serial No.________________________________
________________________________________ Manufactured Year________________________
________________________________________ Last Serviced_____________________________
________________________________________ Odometer reading ________________________

Parts Labour

Part no. Descrip on Price QTY Total Cost Employee name Descrip on Time taken
of work
performed

1.

2.

3.

4.
5.

6.

Mechanics comments Cost of parts

______________________ Labour cost
________________________________________ Total cost
Inspected
By______________________________

Fig.6.2.10 Sample Record Order

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6.2.7 Health and Safety Measures

It is important to follow health and safety measures at workplace to protect men, material and
machines. Every organisa on has to be complaint with health and safety guidelines provided by the
State and legal authori es. Electric vehicles comprise of high-voltage components and other aggregates
that require safe handling to prevent injuries, death or damage to equipment and workplace. It is
important to make note of all the safety measures outlined by the manufacturers. A workshop poses
many risks like electric shocks, fire, explosion, exposure to ba ery acids, fumes, slips and falls, etc. Some
of these risks can also pose problems to components and equipment like corrosion, damage,
deforma on, etc. the presence of HV components can be a threat to other components inside and
outside the vehicle. Therefore, it has to be ensured proper insula on and handling techniques are
followed. Workers should wear appropriate PPE, use insulated and recommended tools and follow safe
prac ces. Employees should be trained in proper disposal of hazardous, non-hazardous and recyclable
wastes to prevent damage to humans, workplace and environment.

Summary
Ÿ Electric 2/3-wheelers are plug-in electric vehicles with two or three wheels. The electricity is stored
in a rechargeable ba ery which drives one or more motors.
Ÿ The various mechanical components are drive train, brake, suspension, steering, chassis, body,
wheels and tyres.
Ÿ The various electrical/electronic components are ba ery, motor, relays (switching components),
control units, on-board charger, charging points, isolators (safety devices), inverter (DC to DC
converter), ba ery management system (BMS), igni on or key-on control switch, and display
panel.
Ÿ Like in all EVs, ba eries, motor and motor controller unit are the main components which drive the
electric 2/3-wheelers. These electrical components are connected to the transmission system.
Ÿ Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security
has to be followed. The job card has to be obtained and the work that needs to be done has to be
analysed and understood. All the technical data required should be obtained from OEM manuals
and from the Lead Technician.
Ÿ It is important to know the specifica ons of the vehicle before taking up any work on the vehicle.
This will help to check if all the parameters are as specified and makes fault finding easier.
Ÿ The various tools and equipment used in maintenance, servicing and repairing of EVs can be
broadly classified as tools, tes ng equipment and workshop equipment.
Ÿ Pre-service visual inspec on helps the service team to assess the problems/faults in the vehicle in
addi on to customer complaints. This also helps to organize for the tools, spare parts and other
equipment that are likely to be required.
Ÿ A er carrying out inspec on of the vehicle, a note of all the parts that are damaged, worn out,
contaminated, malfunc oning, etc. should be made. If some of the faults are beyond the scope of
EVST, then it has to be escalated to the Lead Technician. All other servicing and repair work can be
carried out as per OEM instruc ons.

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Ÿ Diagnosis of fault in vehicle components is carried out by finding the fault by means of its
symptoms, appearance, conduc ng tests using measuring devices, applying knowledge, etc. The
cause for the fault has to be determined and then remedial ac on has to be taken. Technicians
should analyse the reason for faults or failure.
Ÿ A er comple ng servicing/repair work, the cable connector, nuts, bolts and fasteners and control
switches have to be inspected.
Ÿ Documenta on helps in keeping track of all the work carried out. It is a good prac ce to keep a
record of the vehicle model number, serial numbers, parts, specifica ons of all the components,
etc.
Ÿ It is important to follow health and safety measures at workplace to protect men, material and
machines. Every organisa on has to be complaint with health and safety guidelines provided by
the State and legal authori es. Electric vehicles comprise of high-voltage components and other
aggregates that require safe handling to prevent injuries, death or damage to equipment and
workplace.

Exercise
Answer the following ques ons:
1. Explain the basic technology of a 2/3-wheeler EV.
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
2. Briefly discuss the steps to be taken while performing servicing/repair work on a 2/3-wheeler EV.
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

Scan the QR Code to watch the related video

www.youtube.com/watch?v=j4cqOHUV22I&t=509s
How To Service & Maintain Tunwal Bikes

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7. Perform rou ne
service and repairs
of a truck/bus
electric vehicle

Unit 7.1 - Basics of Truck/Bus Electric Vehicle

Unit 7.2 - Rou ne Service and Repairs on a Truck/Bus
Electric Vehicle

ASC/N1452
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Key Learning Objec ves

At the end of this module, the trainee will be able to:
1. Demonstrate preparatory ac vi es for diagnosing faults and repairing of a truck/bus electric vehicle
2. Demonstrate how to use different techniques for diagnosing faults and repairing the truck/bus
electric vehicle

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Unit 7.1 - Basics of Truck/Bus Electric Vehicle

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. List various components /aggregates and the manufacturer's specifica ons of a truck/bus EV
2. Discuss basic technology used, func oning and interconnec ons of various systems and components
of a truck/bus EV

7.1.1Basics of Truck/Bus EV
Electric trucks or buses are electric vehicles that replace conven onal internal combus on engines and
transmissions with electric motors and onboard high-voltage ba eries. The minimum voltage required
to run an electric truck or bus is 400V to 800V. Electricity is stored in a rechargeable ba ery which drives
one or more motors. Most of these EVs are powered by Lithium-ion ba eries and they can be charged by
plugging into ordinary wall outlets.
The main mechanical components in an EV Truck/Bus are:

Chassis

Body

Drive train

Brake system

Suspension system

Steering system

Wheels and Tyres

Axle

Fig. 7.1.1 Main Mechanical components in an EV Truck/Bus

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Chassis: The Chassis of a truck or bus holds together the body, motor, ba eries, suspension, steering
system, seat, wheels, tyres, etc. It bears the weight of the whole vehicle, the weight of the people riding,
and any addi onal load like luggage and cargo. It also withstands stresses during accelera on, braking,
and bad road condi ons.

(a) (b)

Fig. 7.1.2 (a). Chassis of an Electric Truck (b). Chassis of an Electric Bus
(a: h ps://cleantechnica.com/2015/03/02/frankenstein-electric-trucks-ford-f59-chassis/)
(b: h ps://www.volvobuses.com/en/city-and-intercity/chassis/volvo-bzl-electric/specifica ons.html)

Body: It is the super-structure of a vehicle and is a ached to the chassis.

Fig. 7.1.3 Electric Truck Body

chrome-extension:// eoggkfdfchfphceeifdbepaooicaho/html/site_status_block_page.html

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Fig. 7.1.4 Electric Bus Body

h ps://www.transi raining.net/images/uploads/full_documents/BEB_Session_1_Slides_and_Notes.pdf

Note: The loca on of components and nomenclature differs by OEM.

Drivetrain: The main func on of the drivetrain is to deliver the power generated by the motor to the
drive wheels. It consists of the torque converter, transmission, propeller sha , differen al and axles.

Fig. 7.1.5 Drivetrain in an Electric Truck

(Source: h ps://www.piercemfg.com/electric-fire-trucks/pierce-volterra )

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Suspension: The suspension system consists of tyres, springs, shock absorbers, and linkages that
connect a vehicle to the wheels. It helps in vehicle’s road-holding, and braking, providing comfort,
reducing stress on the vehicle due to road shocks, and providing the required height for the vehicle.

Fig. 7.1.6 Suspension System

(Source: h ps://www.liveabout.com/pickup-truck-suspension-systems-327393 )

Notes

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 Electric Vehicle Service Technician

Steering: It contains the steering wheel, steering column, gears, linkages, etc. It helps the driver control
and turn the vehicle, provides stability, and reduces vibra ons and wear and tear of tyres.

Fig. 7.1.7 Steering System

Source: h ps://www.larescorp.com/toolbox/skinned-knuckles-ar cles/manual-steering-gear-and-linkage

Brakes: Brake is a mechanical device used to stop or slow down the vehicle. Air brakes are widely used in
trucks and buses. Compressed air is used in air brakes. It can be either disc brakes, drum brakes, or a
combina on of both.

Fig. 7.1.8 Air Brake System

Source: h ps://knilt.arcc.albany.edu/Unit_2:_Air_Brakes_in_Commercial_Vehicles

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Wheel and Tyres: It helps in suppor ng the weight of the vehicle, absorb road shocks, grip the road
surface, and balance the vehicle in mo on and rest. Tyres are mounted on the wheel disc. It provides
good grip, carries the load of the vehicle, absorbs road shocks, reduces vibra ons and gives cushioning
effect to the vehicle.

Fig. 7.1.9 Wheel and Tyre

h ps://www.shu erstock.com/search/bus-wheel

Axle: The rod or sha that rotates the wheels and bears the weight of the vehicle is called as axle. Mul
axles are used in trucks and buses for carrying more load.

Fig. 7.1.10 Electric Axle of EV Truck/Bus

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Acronyms used in EV Truck/Bus:

Acronym Meaning

ABS An -Lock Braking System

AC Alterna ng Current

BEB Ba ery Electric Bus

BMS Ba ery Management System

CAN Controller Area Network

DC Direct Current

ECU Electronic Control Unit

EMI Electromagne c Interference

ESS Energy Storage System

HV High Voltage

HVIL High Voltage Interlock Loop

HVJB High Voltage Junc on Box

IGBT Insulated Gate Bipolar Transistor

LOTO Lock-Out Tag-Out

LV Low Voltage

MSD Manual Service Disconnect

MUX Mul plex

TM Trac on Motor

Table 7.1.1 Acronyms used in EV Truck/Bus

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Main Components of EV Truck/Bus:

Truck/Bus EV The main electrical components in a Truck/Bus EV are:

Name of the electrical Image

component

Ba ery

Lithium-ion ba ery (Source: www.indiamart.com)

Motor

Brushless DC motor (Source: www.indiamart.com)

Control units

(Source: www.alibaba.com)

High Voltage Cable

h ps://cv.egelectronics.com/products/electric-vehicles/ev-
high-voltage-cables/

Con nued...

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Name of the electrical Image

component

High Voltage Junc on Box (HVJB)

h ps://in.pinterest.com/pin/288371182400547109/

On-Board Charger

(Source: www.amazon.com)

Charging port

Con nued...

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Name of the electrical Image

component

Inverter (DC-DC converter)

(Source: www.amazon.com)

BMS

(Source: www.financialexpress.com)

Contactor

h ps://www.environmentalengineering.org.uk/news/high-
performance-contactor-for-use-in-ev-equipment-4604/

Con nued...

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 Electric Vehicle Service Technician

Name of the electrical Image

component

Trac on Motor

h ps://www.automo veev.com/nidec-adds-two-new-
models-to-its-lineup-of-ev-trac on-motor-systems/

Overhead Charging

h ps://www.schunk-group.com/en/news-and-trade-
shows/current-topics/ideal-solu ons-for-electric-bus-
charging

Table 7.1.2 Main Electrical Components in an EV Truck/Bus

Notes

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7.1.2 Basic Technology of Truck/Bus EV

Fig. 7.1.11 Basic Technology of Electric Truck

(Source: h ps://ecochamps.eu/medium-duty-commercial-iveco-daily-hybrid-plug-in/)

Fig. 7.1.12 Basic Technology Electric Bus

(Source: h ps://onwardstate.com/2017/03/03/cata-u lizing-electric-bus-march-13-17/ )

Like in all EVs, ba eries, motor and motor controller units are the main components which drive the
electric trucks and buses. These electrical components are connected to the transmission system. The
rechargeable ba eries are the energy source that is charged by taking electric current from the grid. The
controller unit then controls the flow of energy from the ba ery to the motor. The motor in turn
transmits the power to the wheels of the vehicle with the help of the transmission system or directly to
the wheel (in-wheel motor).

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7.1.3 Interconnec ons of Various Components in Truck/Bus EV

The following figure shows the generic block diagram and wiring diagram of a Hybrid Electric truck/ bus.

Fig. 7.1.13 Block Diagram of Hybrid Truck/Bus

(Source: h ps://www.seman cscholar.org/paper/Integrated-chargers-for-EV%27s-and-PHEV%27s%
3A-examples-Haghbin-Khan/90d1138d2eae69380880701ce0d1b4b8 d681ac/figure/0)

The following figure shows the generic wiring diagram of a Truck/Bus EV.

Fig. 7.1.14 Wiring Diagram of Truck/Bus EV

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Unit 7.2 - Rou ne Service and Repairs on a Truck/Bus EV

Unit Objec ve
At the end of this unit, the trainee will be able to:
1. List the types of tools and equipment used in different processes of a truck/bus EV maintenance
2. List the ac vi es need to perform for preparing a truck/bus EV for fault iden fica on and repairing
work
3. Discuss the symptoms of technical faults, their causes and rec fica on procedures in a truck/bus EV
4. Explain the health and safety measures and regula ons w.r.t. equipment and components during
fault diagnosis

7.2.1 Prepare to Perform Rou ne Service and Repairs on a

Truck/Bus EV
Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security must
be followed. The job card must be obtained and the work that needs to be done has to be analysed and
understood. All the technical data required should be obtained from OEM manuals and the Lead
Technician. It is a legal requirement for EV workshops to protect their people and workplace from
poten al risks especially while dealing with High-Voltage components. This can be achieved by carrying
out a risk assessment, training workers in safe work prac ces and maintaining a safe work environment.

7.2.2 Guidelines for Service/Repair of Truck/Bus EV

Only trained personnel should carry work on Evs.

Always wear appropriate PPE for the work being carried out.

Always use recommended tools and equipment.

Always follow OEMs instruc ons during servicing, maintaining and repairing of the vehicle.

Ensure that the place where maintenance is being carried out is well ven lated and authorized area.

Remove keys from the key switch and remove the ba ery wire before any work.

Deenergize the system as per OEM instruc ons.

Con nued...

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 Electric Vehicle Service Technician

Always use correct ways of handling HV components.

Always use insulated tools while working on electrical components.

Always check the polarity of the ba ery terminal and rewire correctly.

Always use OEM approved spare parts while replacing parts.

Li , hoist and secure the vehicle as per the OEMs recommenda on.

Always block chassis before working underneath it.

Always carry out maintenance work away from sources of exposed flame.

Replace missing or damaged warning, informa on or cau on labels.

Be aware of the common risks in workshops and steps to prevent them.

Be aware or emergency response techniques.

Be aware the procedures to record and report faults that cannot be rec fied by self.

Always maintain documents of all the work carried out on the vehicle.

Fig. 7.2.1 Guidelines for Service/Repair of Truck/Bus EV

Notes

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7.2.3 Specifica ons of the Vehicle

It is important to know the specifica ons of the vehicle before taking up any work on the vehicle. This
will help to check if all the parameters are as specified and make fault finding easier. Apart from
diagnosis, it will also help to cross-check the parameters a er servicing.

Note: Refer to the OEM manual for the specifica ons related to a par cular Model of the vehicle.

Some of the overall specifica ons are:

Dimensions of the vehicle (Length,Width,Height,Wheelbase,Ground Clearance).

Type of vehicle frame.

Load bearing capacity

Gross vehicle weight

Kerb weight

Wheel and tyre:

• Specifica ons of front tyre

• Type of front rim
• Air pressure of front tyre
• Specifica on of rear tyre/tyres
• Type of rear wheel/wheels
• Air pressure of rear tyre/tyres

Suspension system:

• Front shock absorber

• Rear shock absorber

Brake:

• Type of front brake

• Type of rear brake

Fig. 7.2.2 Overall Specifica ons of Truck/Bus EV

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Some of the motor and motor controller system specifica ons are:

Motor:

• Motor type
• Controller type
• Rated voltage
• Rated power
• Maximum motor power
• Maximum motor torque

Controller:

• Rated voltage
• Undervoltage protec on
• Maximum current of the controller

Fig. 7.2.3 Motor and Motor Controller System Specifica ons of Truck/Bus EV

Some of the ba ery and ba ery charger system specifica ons are:

Ba ery:

• Ba ery type
• Rated voltage
• Rated capacity
• Range

Charger:

• Rated output voltage

• Rated output current
• Charging me (Normal and Fast charging)

Fig. 7.2.4 Ba ery and Ba ery Charger System Specifica ons of Truck/Bus EV

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Some of the braking system specifica ons are:

Diameter of front brake disc

Thickness of front brake disc

Thickness of front brake pad

Diameter of rear brake disc

Thickness of rear brake disc

Thickness of rear brake pad

Brake fluid

Fig. 7.2.5 Braking System Specifica ons of Truck/Bus EV

Some of the ligh ng and display specifica ons are:

Head light

Rear tail lamp/lamps

Fog lamps

Turning signal lights

Interior lights

Brake light

Instrument cluster

Infotainment system

GPS naviga on system

USB charging interface

Central control unit

Fig. 7.2.6 Ligh ng and Display Specifica ons of Truck/Bus EV

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 Electric Vehicle Service Technician

Some of the ligh ng and display specifica ons are:

Following are the technical specifica ons of IPL TECH RHINO 5536 Electric Truck:

Specifica on Value

Motor Type Permanent Magnet Synchronous Motor (PMSM)

Ba ery Li-Ion (Refrigerant Cooling)

Maximum Power 360 hp @ 1200rpm

Maximum Torque 2400 Nm @ 600rpm

Clutch 380 mm Día Dry Fric on

Transmission 12 Speed AMT

Charging Time 90 minutes

Range 185 km (Single Charge)

Table 7.2.1 Rhino 5536 Electric Truck Specifica ons

Fig. 7.2.7 Rhino 5536 Electric Truck

h p://www.ipltelectric.com/rhino.php

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Par cipant Handbook

TATA Ultra 9/9m Electric Bus Specifica ons:

Following are the technical specifica ons of TATA Ultra 9/9m Electric Bus:

Specifica on Value

Motor Type Integrated Motor Generator

Maximum Power 245 kW

Con nuous Power 145 kW

Maximum Motor Torque 3000 Nm

Con nuous Torque 1145 Nm

Ba ery Pack Li-Ion Ba ery Pack

Ba ery Capacity Capacity: 124 kW-hr (Expandable)

Charging Time ~ 2 to 2.5 hrs. with fast charging

Range >150Kms (as per Standard test condi ons/CMVR)

Maximum Speed 75 km/h

Accelera on 0-30 km/hr. >=0.8 m/sec^2

<= 10.5 Sec

Grade-ability Min 17% @ Rated GVW

Suspension Air Suspension

Brakes Dual circuit full air S-cam brake with EBS (Op onal)
and front disc brakes

Sea ng Layout 31+D

LV System Voltage 24 V

Wheel Base 4920 mm

Floor Height 900 mm

Overall Width 2340 mm

Turning Circle Diameter 17.5 m

Gross Vehicle Weight 10200 +/- 300 kg

Table 7.2.2 Ultra 9/9m Electric Bus Specifica ons

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 Electric Vehicle Service Technician

Fig 7.2.8 TATA Ultra 9/9m Electric Bus

h ps://www.buses.tatamotors.com/products/brands/starbus/tata-ultra-9-9m-ac-electric-bus/

Notes

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7.2.4 Tools and Equipment

The various tools and equipment used in the maintenance, servicing and repairing of EVs can be broadly
classified as tools, tes ng equipment and workshop equipment.

Tools Image

Spanner is used to provide grip while

applying torque to objects like nuts
and bolts. The most common types of
spanners are open and ring spanners.

A socket wrench is a type of spanner

that has a closed socket format.

Screwdrivers are used to remove and

install screws. They can be manually
operated or power operated.

Pliers and Wire cu ers are used to grip

small objects, hold wires, bend wires,
loops and a ach wires. They can also be
used to cut wires with minimal damage
to the insula on or internal conductors.

Hex or Allen key wrenches are used to

drive bolts and screws with a
hexagonal socket.

Source: www.amazon.com

Con nued...

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 Electric Vehicle Service Technician

Tools Image

Tyre spoon levers are used to

separate tyres from the wheels.

Source: www.amazon.com

Adjustable locking spanner wrenches

are used to grip fasteners like nuts
and bolts of all sizes.

Source: www.amazon.com

Torque wrenches are used to apply a

specific torque to nuts and bolts.

Impact wrenches are used to deliver

high torque output with minimal
exer on by the user. They are used
along with impact sockets.

Con nued...

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Par cipant Handbook

Tools Image

Bearing pullers are used to remove

components like gears, pulleys,
bearing, etc. from sha s.

Source: www.engineeringtools.com

Tyre pressure gauges are used to

measure the pressure in inflated
tyres on the wheels of vehicles.

Measuring equipment

Vernier callipers are used to measure

the inner and outer dimensions of
objects.

Micrometers are used to measure

the thickness, diameter and length of
solid objects.

Con nued...

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 Electric Vehicle Service Technician

Tools Image

Feeler gauges are used to measure

the gap between two parts.

Source: www.amazon.com

Mul meters are also known as

Volt/Ohm meters or VOM, they are
used to measure voltage, resistance,
and current

Dial gauges are used to measure

minute lengths and displacement
accurately.

www.upload.wikimedia.org

Ba ery hydrometers are used to

measure the specific gravity (density)
of the ba ery's electrolyte, which
helps in determining the state of
charge of the ba ery.

Source: www.indiamart.com
Con nued...

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Par cipant Handbook

Tools Image

Ba ery maintenance kits contain

insulated tools and other devices
required for ba ery maintenance.

Workshop equipment

Electric drills or power drills are used

to make a hole in a variety of
materials and also to drive screws
through different materials.

Cranes are used to li and lower or

move material and objects
horizontally with help of hoist chains
and cables.

Source: www.indiamart.com

Hydraulic hoists are used to li

vehicles so that repair and
maintenance work on the
undercarriage of vehicles can be
carried out.

Source: www.indiamart.com

Con nued...

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 Electric Vehicle Service Technician

Tools Image

Source: h ps://mitgroup.en.made-in-
china.com/product/TdlaECQUTIRx/China-Maxima-
Hydraulic-Truck-Li -7-5t-Capacity-CE-Cer fied-Truck-Bus-
Maintenance-FC75.html

Jack and axle stand is used to support

the weight of vehicles and hold it in
place while replacing tyres and other
parts under the vehicle.

Source: www.indiamart.com

Trolley jack is used to li a part of a

vehicle via its chassis.

Source: www.indiamart.com

Wheel chocks are used to prevent the

move movement of wheels while
servicing the vehicle.

Source: h ps://www.shu erstock.com/search/wheel-

chocks

Table 7.2.3 Tools, Measuring Devices and Workshop Equipment

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7.2.5 Visual Inspec on of Truck/Bus EV

The pre-service visual inspec on helps the service team to assess the problems/faults in the vehicle in
addi on to customer complaints. This also helps to organize the tools, spare parts and other equipment
that are likely to be required. The vehicle has to be set on flat ground before the inspec on. Inspec on of
the following parts of the vehicle has to be carried out:

Part Inspec on item Inspec on observa on

Appearance Outer parts

Screws, fasteners, nuts and

bolts

Front and rear shock absorbers

Damages, deforma ons, etc.

Dents and Scratches

Fixed assembling Differen al

Steering

Transmission

Front and rear tyres

Front and rear wheels and

wheel-hub assembly

Front and rear axles

Front and rear suspension

Braking system Appearance

Assembly clearance

Abnormal brake noise

Brake fluid volume

Response me

Braking distance

Brake Discs and Drums

Brake pedal

Brake lining

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 Electric Vehicle Service Technician

Part Inspec on item Inspec on observa on

Braking system Air brake pressure

Air compressor

Governor

Electronic components Ligh ng

Power lock

Instrument cluster

Vehicle insula on

Alarm and horn

EBS energy recovery

Controller

Wheel-hub motor Appearance and wire

connec on

Startup

Abnormal noise

Tolerance

Deforma on

So ware Display so ware version

ECU so ware version

FOC so ware version

BMS se ng

Table 7.2.4 Checklist for Visual Inspec on of Truck/Bus EV

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7.2.6 Carryout Vehicle Inspec on

The Motor Compartment of Electric Truck/Bus typically consists of:
• High voltage components
• Coolant reservoir
• Low-voltage ba ery
• Fuse box
• Brake fluid reservoir
• Windshield washer fluid reservoir
Electric Truck Motor Compartment

Fig 7.2.9 Electric Truck Motor Compartment

h ps://www.northbaybusinessjournal.com/ar cle/ar cle/california-eyes-requiring-sales-of-zero-emission-trucks/

Electric Bus Motor Compartment

Fig 7.2.10 Electric Bus Motor Compartment

h ps://www.alamy.com/stock-photo/motor-of-electric-bus.html

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 Electric Vehicle Service Technician

Steps to Carry out Inspec on

• Check steering wheel.

• Check steering column.
• Check steering control unit.
• Check steering gerabox
• Check universal joint.
Inspec on
• Check e rod.
of Steering
• Check fluid lines.
• Check rack and Pinion.
• Check reservoir
• Check sensors
• Check pitman arm.

• Check brake fluid level.

• Check the brake discs.
• Check ABS control module.
• Check master cylinder.
Inspec on of
• Check hydraulic lines.
Brake system
• Check the brake pedal
• Check brake lining wearing.
• Check the brake drum.
• Check the brake caliper

• Check the en re front and rear shock absorber assembly for leakage,
damages or loosened fasteners.
• Check the func on of damper spring.
• Check the stabilizer bar.
• Check ball joint.
Inspec on of
Suspension • Check the lower and upper control arm.
System • Check e rod end.
• Check the coil springs.
• Check the compensator arm.
• Check the trailing arm.
• Check the bearing and hub.

Con nued...

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• Check the rota on of the wheels.

• Check if the wheel bearings have loosened.
Inspec on of • Check the wheel bearings for wearing.
Wheels and • Check tyre pressure with pressure gauge.
Tyres
• Check tyres for cuts, damages or embedded sharp objects.
• Check tread depth.
• Check flatness of front and rear wheels.

• Turn on the igni on switch and check the right and le combina on
switches.
• Check head light.
• Check le and right turn signal lamps.
• Check tail lamp.
Inspec on of
Lights • Check the light intensity and flashing.
and electricals • Check if switching between high and low beams are normal.
• Check if brake lamp turns on when brake is applied.
• Check if the horn sound is normal.
• Check for normal opera on of startup bu on.
• Check for normal opera on of speed regula on switch.

• Check ba ery for normal performance.

• Check motor system.
• Check hall cable-sensor, sensor connector, power supply.
• Check hall motor connector and controller connector.
• Check FOC controller:
◦ Indicator for flashing frequency for warnings.
Inspec on of ◦ Power input.
electrical ◦ ACC wire of alarm for closed circuit.
system
• Check DC-DC convertor power input and output.
• Check power-lock.
• Check ECU.
• Check side stand switch.
• Check brake switch.
• Check charging port.
• Check display as per the diagnos c code.
Con nued...

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• Check ba eries for normal performance.

• Check electrolyte level.
Inspec on of
• Check charge.
Ba eries
• Check terminals and ba ery compartment.
• Test ba eries.

• Check coolant level in coolant reservoir.

• Check accelerator handle for smooth opening and automa c rese ng at
Inspec on of
all steering posi ons of the steering handle.
Cooling system
• Check the accelerator handle cable if accelerator handle cannot be reset
as usual.

Fig. 7.2.11 Steps to Carryout Inspec on of Truck/Bus EV

Notes

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7.2.6 Preven ve Maintenance of Truck/Bus EV

Some of the preven ve maintenance ac vi es for various components are listed below:
Ini al PM
Motor Run-in
1. Lubricate the bearings a er 1500 kms
2. Grease trac on motor fi ngs
Weekly PM
1. Vehicle’s HVAC system should be checked weekly once

Fig 7.2.12 HVAC System

h ps://www.transi raining.net/images/uploads/full_documents/BEB_Session_1_Slides_and_Notes.pdf

Monthly PM
The following components to be checked during monthly preven ve maintenance:
1. Ba ery pack cell voltage
2. Ba ery charging and balance
3. Trac on motor

Fig 7.2.13 Components to be checked during monthly PM

(Source:h ps://www.transi raining.net/images/uploads/full_documents/BEB_Session_1_Slides_and_Notes.pdf)

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Quarterly PM
The following components to be checked during quarterly preven ve maintenance:
1. ESS ba ery chiller
2. High voltage cable
3. LV (25 VDC) electrical wiring
4. Rear ba ery strings
5. Roof top ba ery strings
6. DC-DC converter
7. Roof top electronics enclosure
8. Power steering
9. Air compressor
10. Trac on motor
11. Charging cable receptacle
12. HV accessory cable
Six-Month PM
The following components to be checked once in every six months:
1. HVAC system
2. Coolant fluid
Annual PM
The following components to be checked once in every six months:
1. Low voltage distribu on box
2. High voltage distribu on box
3. Auxiliary power distribu on box
4. Insula on monitoring device
5. Ba ery pack

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7.2.7 Perform Rou ne Service and Repairs on a Truck/Bus EV

A er inspec ng the vehicle, a note of all the parts that are damaged, worn out, contaminated,
malfunc oning, etc. should be made. If some of the faults are beyond the scope of EVST, then it has to be
escalated to the Lead Technician. All other servicing and repair work can be carried out as per OEM
instruc ons. The Service Technician should wear the required PPE, follow all safety precau ons and use
appropriate tools to work. To perform servicing and repair work, the first step is to remove the external
parts to gain access to the internal parts. Next, the internal parts must be inspected to see if there are
any faults, find the cause, take remedial ac on and then reinstall all the parts back in their place.
Steps to Dismantle all the External Parts of a Truck/Bus EV
The following are the parts to be removed to inspect the internal parts of the vehicle (it is an indica ve
process. Please follow the sequence suggested by the OEM):

Remove front and rear wheels.

Open the front bonnet.

Disconnect the connectors and pull the ba ery compartment lock cable.

Remove end cap and ba ery cover.

Unplug the USB output cable.

Unplug the power lock connector and remove the power lock.

Unplug the dashboard cable and remove the display.

Plug the brake connector and remove the front/rear brake system.

Remove the motor connectors on FOC (field-oriented control) controller.

Remove the motor.

Remove the ba ery.

Remove the controller.

Remove the inverter.

Fig 7.2.104Steps to Dismantle all the External Parts of a Truck/Bus EV

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7.2.8 Diagnosis of Faults in a Truck/Bus EV

Diagnosis of fault in the vehicle components is carried out by finding the fault using its symptoms, and
appearance, and conduc ng tests using measuring devices, applying knowledge, etc. The cause for the
fault has to be determined and then remedial ac on has to be taken. Technicians should analyse the
reason for faults or failure. For example: if a part is worn out, then it should be analysed to see if it was
due to normal wear and tear or due to other abnormal condi ons like shock, fa gue, overloading,
improper lubrica on, improper maintenance, etc. The most common reasons for a part failure are:

Poor preven ve maintenance or inspec ons.

Poor design of the part.

Improper use of the part.

Wrong usage or driver abuse.

Fig 7.2.15 Common Reasons for a Premature Component Failure

Some of the common faults observed in a truck/bus EV are listed below:

• Over hea ng.

• Slow charging.
• Over charge.
• Quick discharge.
• Short circuit.
• Leakage.
Ba ery Pack • Swelling.
• Fire.
• Sensor failure.
• Cooling system failure.
• Cell degrada on.
• Loose terminals.
• Corroded terminals.

Con nued...

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• Charger not working.

• Electrical fault (Earth).
• Thermal cutoff.
• Tripping issue.
• Do not charge 100%.
• Broken cable.
Charger
• Broken socket.
• Broken plug.
• Release bu on not func oning.
• Broken latch.
• Control box not func oning.
• Over hea ng.

• Abnormal noise.
• Jerky opera on.
• Hall sensor fault.
• Vehile does not move in reverse direc on.
• Vehicle does not move in forward direc on.
• Vehicle does not move.
• Vehicle runs in slow speed.
• Over Hea ng.
Motor • Vibra ons.
• Winding issues.
• Over load.
• Short circuit.
• Rotor faults.
• Stator faults.
• Bearing faults.
• Eccentricity related faults.
• Bend sha .

Con nued...

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• Over Hea ng.

• Too much power consump on.
• Loose connec ons.
• Tripping.
Invertor
• Faulty/Weak ba ery.
• Overload.
• Short circuit.
• Not charging.

• MOSFET issues.
• Motor phase loss.
• IC issues
Controller • Sensor issues.
• Short circuit.
• Insufficient power.
• Faulty wires.

• Dust/Mud accumula on.

Charging Port • Broken lid.
• Water accumula on.

• Electromagne c compa bility issues.

• Output voltage is lower than input voltage.
DC-DC Converter • Output voltage is higher than input voltage.
• Unwanted electrical and electromagne c signal noise.
• Loosened terminal screws.

Con nued...

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• Inadequate air-fuel mixture.

• Coolant leakage.
• Worn spark plugs.
• Carburetor issues.
• Oxygen sensor issues.
• Engine knocking.
• Engine detona on.
• Poor lubrica on.
IC Engine • Clogged radiator.
• Overhea ng.
• Timing chain failure.
• Smoke from the engine.
• Gasket problems.
• Manifold issues.
• Stalling.
• Piston and Piston ring issues.
• Crank and Cam sha issues.

• Gear slipping.
• Transmission fluid leakage.
• Gears grinding.
• Noise and Vibra on
Transmission • Over hea ng.
• Shaking.
• Hard gear shi s.
• Engine stalls at low speed.
• Burning smell.

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• Thermal runaway
• Short circuit.
• Wiring harness damage.
• High/Low voltage.
• ECU failure.
BMS • Cooling fan failure.
• SOC faults.
• Insula on faults.
• Sensor faults.
• Over charge/discharge.
• Over hea ng.

• Tyre pressure is too low or insufficient

• Air leakage from tyre
• Axle is deflected
• Wheel deformed and tyre is deflected
• Wheel vibrates/wobbles
Tyres • Axle bearing is loosened
• Tyre is deteriorated
• Wheel is difficult to turn
• Axle bearing has failed
• Braking is bad
• Misalignment

• Steering wheel vibra ons

• Power steering fluid leakage
Steering System • Steering handle is difficult to turn
• Steering is unstable
• Noisy steering

Con nued...

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• Bad shocks and struts

• Damaged springs
• Ball joints failure
• Bad control arms
• Worn-out parts
• Oil leakage from shock absorber
Suspension System
• S ffness in the shock absorber spring
• Hardened shock absorber
• Deflec on in shock absorber rod
• Abnormal noise from suspension
• Bumpy rides
• Poor wheel alignment

• Poor brake performance

• Failure of hydraulic disc brake
• Brake assembly not installed properly
• High or low level of brake fluid in the main brake reservoir
• Blockage of fluid flow channel
• Air leakage in brake caliper, brake hose and hose joint
• Sponge-like feeling while opera ng brake handle
• Presence of air in brake system oil circuit
Brake system • Wearing of brake disc and brake pad
• Deforma on and bending of brake pad
• Contamina on of brake disc and brake pad
• Excessive wearing or damage in main brake pump piston
surface and oil cylinder wall surface
• Cracks, damages and wearing out of main brake piston cup
• Excessive wearing or damage in brake caliper pump piston
surface and oil cylinder wall surface
• Abnormal noise from the brake
• ABS failure

Fig. 7.2.16 Common Faults Observed in Truck/Bus EV

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7.2.9 Causes and Remedies for Some Important Faults:

The following table shows the causes and remedies for some of the important faults in Truck/Bus EV:

Fault Cause Remedy

Wheels vibrates/wobbles Damaged wheels, improper Replace damaged wheels,

wheel and tyre balance, the perform wheel alignment,
u n e v e n w e a r i n g o f t y re , replace worn-out tyres Adjust
improper tyre pressure, loose tyre pressure, ghten of lug
lug nuts, etc. nuts, etc.

Wheel is difficult to turn Worn out spindle bearing Replace the spindle bearing

Steering wheel is difficult to turn Steering column bearing is too Loosen the steering column
ght, Internal bearings of the bearing, clean and adjust the
Steering is unstable
steering column are clogged steering column, replace the
with debris, damaged steering damaged damper
damper

Rota on of the wheels are Improper wheel balancing, Perform wheel balancing,
irregular damaged wheels, improper replace damaged wheels,
transmission, improper tyre check transmission, adjust tyre
pressure, etc. pressure

Poor brake performance Damaged brake cables, Replace all damaged cables,
damaged components, c o m p o n e n t s a n d t o rs i o n
corrosion and damage to springs, and correct brake
to rs i o n s p r i n g , i m p ro p e r se ngs
se ngs

Table 7.2.5 Causes and Remedies for Some Important Faults

Notes

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7.2.10 Post Rou ne Service and Repairs on a Truck/Bus EV

A er comple ng servicing/repair work, the cable connector, nuts, bolts and fasteners and control
switches have to be inspected.

• Check cables a er clamping to ensure electric safety.

• Cables should be bound with adhesive tapes at the designated
posi ons.
• Cables should not be placed at end of screws, bolts and vehicle
frame end.
Inspec on of Cable • Protect cables at a sharp angle or turning posi on with
connector adhesive tapes.
• Cables should be placed without twis ng or tying.
• Controlling cables should not be bent or twisted.
• Ensure that the connector shroud is not damaged or the
connector is not excessively open before connec ng.

• Check if all nuts, bolts and fasteners on the chassis are

Inspec on of nuts, ghtened as per the torque values.
bolts and fasteners • Check if safety clips, split pins, cables and hose clamps are
placed properly and secured ghtly.

• Head lights, tail lights and Indicators

• Accelerator
• Horn
• Brake
• Igni on switch
Inspec on of Control • Display panel
switches • Telema cs Control Unit (TCU)

Fig. 7.2.17 Post Service/Repairs Inspec on in Truck/Bus EV

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A er the comple on of work, all the tools and spare parts have to be returned. All the waste generated
should be segregated and disposed of safely as per the company procedures. The vehicle has to be re-
energized. Assist EVSLT in the diagnosis of faults a er servicing/repairing. The serviced/repaired vehicle
has to be visually examined as per the OEM manual and checked for warning signals, unusual noises,
vibra ons, etc. and then taken for a test ride to check if the vehicle is running at normal levels and
servicing and repairs are successful. Carry out tests using measuring devices if required and compare the
test results with the vehicle specifica ons and regula ons. If certain issues are no ced, seek the advice
of seniors and rec fy the problems by performing addi onal repairs.

7.2.11 Documenta on
Documenta on helps in keeping track of all the work carried out. It is a good prac ce to keep a record of
the vehicle model number, serial numbers, parts, specifica ons of all the components, etc. Keeping a
record of components will help in future to understand its performance, life, wear and tear frequency,
problems if any, etc. Documenta on of the work done will provide a database for future troubleshoo ng
and also planning, as it helps to calculate the man hours taken to solve a certain issue. Documenta on is
also important for legal and organiza onal requirements. A Repair Order is the most common form of
documenta on used in the workshop to document servicing or repair work carried out.

Repair Order

Reason for repair: Date:__________________

________________________________________ Name: __________________________________
________________________________________ Address: ________________________________
________________________________________ ________________________________________
________________________________________ Vehicle Regn.no. __________________________
Instruc ons: Model__________________________________
________________________________________ Serial No.________________________________
________________________________________ Manufactured Year________________________
________________________________________ Last Serviced_____________________________
_______________________________________ Odometer reading ________________________

Parts Labour
Part no. Descrip on Price QTY Total Cost Employee name Descrip on of work Time taken
performed

1.
2.
3.
4.
5.
6.
Mechanics comments ______________________ Cost of parts
________________________________________ Labour cost
Inspected By______________________________ Total cost

Fig.7.2.14 Sample Repair Order

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7.2.12 Health and Safety Measures

It is important to follow health and safety measures at the workplace to protect men, materials, and
machines. Every organiza on has to be compliant with health and safety guidelines provided by the
State and legal authori es. Electric vehicles comprise high-voltage components and other aggregates
that require safe handling to prevent injuries, death, or damage to the equipment and the workplace. It
is important to make note of all the safety measures outlined by the manufacturers. A workshop poses
many risks like electric shocks, fire, explosion, exposure to ba ery acids, fumes, slips and falls, etc. Some
of these risks can also pose problems to components and equipment like corrosion, damage,
deforma on, etc. The presence of HV components can be a threat to other components inside and
outside the vehicle. Therefore, it has to be ensured proper insula on and handling techniques are
followed. Workers should wear appropriate PPE, use insulated and recommended tools, and follow safe
prac ces. Employees should be trained in the proper disposal of hazardous, non-hazardous and
recyclable wastes to prevent damage to humans, the workplace and the environment.

Summary
• The various mechanical components are drivetrain, brake, suspension, steering, chassis, body,
wheels and tyres.
• The various electrical/electronic components are ba ery, motor, relays (switching components),
control units, on-board charger, charging points, isolators (safety devices), inverter (DC to DC
converter), ba ery management system (BMS), igni on or key-on control switch, and display panel.
• Before taking up any prac cal work on an EV, all rules and regula ons related to safety and security
have to be followed. The job card has to be obtained and the work that needs to be done has to be
analysed and understood. All the technical data required should be obtained from OEM manuals
and the Lead Technician.
• It is important to know the specifica ons of the vehicle before taking up any work on the vehicle.
This will help to check if all the parameters are as specified and make fault finding easier.
• The various tools and equipment used in the maintenance, servicing and repairing of EVs can be
broadly classified as tools, tes ng equipment and workshop equipment.
• Pre-service visual inspec on helps the service team assess the problems/faults in the vehicle and
customer complaints. This also helps to organize the tools, spare parts and other equipment that are
likely to be required.
• A er inspec ng the vehicle, a note of all the parts that are damaged, worn out, contaminated,
malfunc oning, etc. should be made. If some of the faults are beyond the scope of EVST, then it has
to be escalated to the Lead Technician. All other servicing and repair work can be carried out as per
OEM instruc ons.
• Diagnosis of fault in the vehicle components is carried out by finding the fault using its symptoms,
and appearance, conduc ng tests using measuring devices, applying knowledge, etc. The cause for
the fault has to be determined and then remedial ac on has to be taken. Technicians should analyse
the reason for faults or failure.
• A er comple ng servicing/repair work, the cable connector, nuts, bolts and fasteners and control
switches have to be inspected.

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• Documenta on helps in keeping track of all the work carried out. It is a good prac ce to keep a
record of the vehicle model number, serial numbers, parts, specifica ons of all the components, etc.
• It is important to follow health and safety measures at the workplace to protect men, materials and
machines. Every organisa on has to be compliant with health and safety guidelines provided by the
State and legal authori es. Electric vehicles comprise high-voltage components and other
aggregates that require safe handling to prevent injuries, death or damage to equipment and the
workplace.

Exercise
Answer the following ques ons:
1. Explain the basic technology of a Truck/Bus EV.
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
2. Briefly discuss the steps to be taken while performing servicing/repair work on a Truck/Bus EV.
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

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8. Employability and
Entreprenuership
Skills

h ps://eskillindia.org/NewEmployability

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9. Annexure

Annexure : QR Code

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Annexure - QR Code

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Annexure - QR Code

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